TWI VM. THE WELDING INSTITUTE ‘Table 10 * Numerical indication of process No. ~ Process No. Process 1 Are welding 47 Gas pressure welding 1 Metabare welding without gas protection 48 Cold welding 11 Metabarc weiding with covered electrode 7 Other welding processes 12 Gravity are weiding with covered clectrode TL Thermit welding 113 Bare wire metal-are welding 72 Blectroslag welding 114 Flux cored metalare welding 73 Blectrogas welding LS Coated wire metalare welding 74 Induction welding 118 Firecracker welding 75 Light radiation welding 12 Submerged arc welding 751 Laser Welding 121 Submerged arc welding with wire electrode 752 Are image welding 122 Submerged are welding with strip electrode 753 Infrared welding 13 Gas shielded metal-arc welding 16 Electron beam welding BI MIG welding 77 Percussion welding 135 MAG welding: metal-are welding with 78 Stud welding onrinert gas shield 136 Flux cored metal- 781 Are stud welding 14 Gas-shielded welding with aon-consumable 782—_~Resistance welding clectrode Mi TG welding 9 Brazing, soldering & braze welding 149 Atomic-hydrogen welding 51 Brazing 15 Plasma are welding 911 Infrared brazing 18 Other ete welding processes 912 Flame brazing 181 Carbon are welding 913 Fumace brazing 185 Rotating are welding 918 Dip brazing 2° Resistance welding 925 Saltbath brazing 21 Spot welding 26 Induction brazing 22 Steam welding 917 Ultrasonic brazing 221 Lap seam welding 918 Resistance brazing 225 Seam welding with strip 519 Diffusion brazing 23 Projection welding 923 Friction brazing 24 Flash welding 224 Vacuum brazing 25 Resistance bent welding 93 Other brazing processes 29 Other resistance welding processes 9 Soldering 291 HP resistance welding 941 Infrared soldering 3 Gas welding 942 Flame soldering 31 Ony-fuel gas welding 543. Fumace soldering 31 Oxyacetylene welding 44 Dip soldering 342 Oxy-propane welding 945 Salt bath soldering 313 Oxy-hydrogen welding 846 Induction soldering 32 Ai fuel gas welding 547 Ultrasonic soldering 321 Aivacetylene wetdin S48 Resistance soldering 322 Air-propane welding 549 Diffusion soldering 4 Solid phase welding: Pressure welding 851 Flow soldering 41 Ultrasonic welding 952 Soldering with soldering iron 42 Faction welding. 953 Frietion soldering 43 Forge welling 954 Vacuum soldering 44 Welding by high mechanical energy 96 Other soldering processes 441 Explosive welding 97 Braze welding 45 Diffusion welding 971 Gasbraze welding 972 Are braze welding * This table complies with International Standard ISO 4063 Welding Inspection — Weld Symbols on Drawings Copyright © 2002 TW Ltd 85 Rev 09-09-02KC4>U onme ZOmN mIBCOKmE moom Page | of CSWIP VISUAL INSPECTION PLATE REPORT Name (Block capitals) A. Buaiceas oRE Signature Test piece identification (& F Code/Specification used Twi Code Bw/vi/oo Welding process MMA, Joint type Sis gus Vee Welding position 4 Go Length & thickness of plate2o0% (& Date Lo-AP2-o Fimo G, Pate Le APe 03 WHLD FACE be — A Seal Cems 4 co MARKS beso 432 Stan Foun ~ we ; OF EMCEE ier Oded FOU LENG OB weed Le2oemn', 923.0% | SUNK maissteg Ton Se ee" eHeBE 97 Tape D= Omnsuarncs . . ie ol SS 7, aR NS Lear nem | Nores LIN ga MISAUGNUBUT Fur toten Leng? Le Zoom; Ds Sum TANGUCAR MISALIQOMEST Full RED LENGTHS L © Pao My Ds Nov MarsuLABLEw BS EN 22553 Fillet Welds Welded arrow side: A continuous fillet weld with a 6 mm leg length, toes to be blended smoothly. » Welded both sides: Three intermittent fillet welds with 6mm leg lengths, the length of each weld 25 mm and the distance between each weld 40 mm. Welded arrow side: Thyee intermittent fillet welds with 10 mm leg lengths, the length of each weld 40 mm, The distance between each weld 30mm, Welded other side: Three intermittent fillet welds 6 mm leg lengths, the length each weld 50mm and the distance between each weld 25mm, welds to be staggered Welded arrow side: Three intermitient Hillet welds with $ mm leg lengths, the length of each weld 25 mm and the distance between each weld 50 mm. Welded other side: Two intermittent fillet welds with 10mm leg lengths, the length of each weld 20 mm and the distance ected es between each weld 40mm, welds to be staggered. Uns Ella 2 onl rerlal / ermal one tha, BegPetr cue ey, 5 tao Ausreame 7 . aso f RUS + Comes te Bcc Fee us sv. oe. CRITICAL. Te mpeentaR y iton aT Bee Cemerre on Bi CFE+ peneute) u yRscreone) 1 My Peteet ce: “1062 a3 IRON CAREo ny RNG RAMMerits and Limitations of NDT Test Methods sin most circumstances post cleaning required Surface preparation critical Technique Uses Merits Limitations Visual Inspection | Surface inspection | ¢Simple to use ‘Inspection of accessible ! of any materials | «Safe surface only : slnexpensive *Surface breaking defects only | +*Rapid results, *Some surface defects may be | No post cleaning missed | required No indication of depths | Dye Penetrant Surface inspection | eSimple to use «Inspection of accessible f of any Ton porous / eInexpensive surface only j materials Rapid results. Surface breaking defects only | . *More sensitive than detected i visual inspection #Very little indication of depths. | *Penetrant may contaminate} component i i i Magnetic Particle Surfa +Simple to use Inspection of accessible surface inspection | «inexpensive surfaces i of magnetic Rapid results *Surface or near surface i materiats slittie surface defects only detected i preparation * Magnetic materials only ‘sMore sensitive than | No indication of depths | visual inspection +Only suitable for linear defects ! Radiography Both surtace and | eLittle surface *Bulky inspection equipment | sub-suace defects | preparation Harmful! radiation i *Permanent record *Defects require significant | Both surface and sub- | depth in relation to the | surface defects radiation beam : detected *Results not normally *No material thickness | immediately available limitations Costly ; Can be carried out on | eVery little ino indication of | most materials, defect depths ! «Not so reliant upon i operator skill, when ' compared to UT. | Ultrasonics Both surface and —_| «Both surface and sub- | ¢Requires high operator skill | sub-sutace defects | surface defects *Good surface finish required | detected *Badly chosen couplant may | Safe contaminate component i *Probe may be driven | «Costly equipment | remotely to ein most circumstances no inaccessible areas permanent record | +Capable of measuring | depth of defects: Welding InspectionTRAINING SAMPLE ONLY MACRO INSTRUCTION/REP ORT SHEET {L.D: AM1031 CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED} THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL JYBLDING PROCESS: [MMA/SMAW] fF ES SDE CTs See SIZE 1 fade oF Sonya Fusion! QS rang 2 | iene Mi SALIGN MEF ibm] Kevees 3 Bung meuused witw Gas Cone Qs Smml Bese 4 Nacho nor wau rusiom wine ass say |} 2mn [CET Ey 5 binuc 2 Sie war Fasion wins siacinee. | ( - Sma | Lester 6 bade oF sie UAL Fusion wim Sen De Smu| ester T [sing inecussed O-B ne 8 les fone 2m 9 [Lage of sims War Fascia lo mm | Regéeq 10 lous vnecadd Peg Oud Reset 11 | EXCESS WELD METAL 2-Sma 12 EXCESS PENETRATION Buomm Goer O-Sam BESET eam nt: Reve, SIGNATURE: Miho DATE . _ ISH ARYL BOOS PRINTFULLNAME: — A2TWWR BaAkemorReTRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [LD: AM1032] CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] Spy SIZE L_ | Lrac of Sine wet Fusion LGum | Resccr 2 ince oF Sioe Wel Fusion! \.amm |Rexser 3_|hauc er Sis Wau Fusion wit Sag Incll 1-2 mm_| Rerbor 4 Nina cfS106 tm Fusion HiT Sug incase] 13 wm | Reser 5 flinvenk MEFALI GNM EIT 1-1 mm | Ceteg _ 6 nce oFsiDe waeerusion ram MELAS Oe mu lesser 7 [Corp var wt toes O-2mn | negee = : eminent ons lu ead Re ren 10 ze Ii [EXCESS WELD METAL [Bom | Resear 12 [EXCESS PENETRATION Zoom | eevee COMMENTS: AN Guta MIKAUGNMENT Novep | [ SIGNATURE: - DATE: fle 42 Apil Qoos PRINT FULL NAME: Agtue BSUNcemoteTRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1034] CHECK PHOTOGRAPH ID MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] MATERIAL: LOW CARBON STEEL WES PROCESS: [MMA/SMAW] ee Sr Gas 2 Olan FO~] 2 many, NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION LASK oF Sing RG Fusion Sure Incuusiol Asioainres Wits Wo.Sewee. | 2-3 MM [sung ingiusto pecooamp win bosuiF. |o 4S mm [Lacie oF Sime Neue Euciod 7 4 Omm INCLUSION ASSeaATED pure Losier. [LOM Soy AG Incusia) ASCCEIRTD wit L-O-5.8-F.|O-2 mm lave oF Sipe rau Fusiod romm 6] eo] ao] ay ops] a) Icenck Like INDLUeTION. 3. 2eayn, 10 |Lammamars 1.3 Panesr Unfonme Il | EXCESS WELD METAL [42mm 12 |42XCESS PENETRATION 13” Camino 1 i — CRUE ISATOSS (9 PACERS MART RD AL = Goren 14 Are Stake coreg 1S Linear thnnuenment . ek! Accser SIGNATURE: be, DATE: _ hi fee~_ 14--m APAL Aoos PRINT FULL NAME: ACTHUR Brarcemoes _ ssOre :Poae Cap FROG RAL WEL Lencty SIMEAE UTR EIMAT BLL WELD LaMeott ALL Dw hengyan) 1 Bim atCOOP T YS BIE ct —t+ Accutane | max aun $ ectiau) TIAL | Atlowtuod We i Re Sect | ui ae ee AccCEPT WED WOK | SLAG INCL USTONS | Nb excur | seit Poee sity [eences + LACK oF, as ESO) (oe = 8 PERM TED 1 AREA Ppeaed ; Ls Ro wsio SOUS E is Ake |_ Sttikes IRECHANICAL DAMAGES caps/ LAR ATION tC ITAGNINENT ARO Cement |A~< | oso ge - | Wham ta S| Me | ~ | = | Accept ¥20 40 TWI training & certitcation a Welding Consumables* Welding consumables used in arc welding may be a combination of flux and bare wire or bare wire without flux. The flux may be coated on the out side of the wire as in the manual metal arc welding process (mma), present as a core as in the fluxed core arc welding process (fcaw) or added separately as a granulated additive in the submerged arc welding process (saw). Consumables, which are added separately to the weld pool as in the tungsten arc welding process (tig), are often referred to as filer wires. If they form part of the electrical circuit they often referred to as electrodes. Welding consumables are: ° > Electrodes + Wire (lengths or spools) » Fluxes + Shielding gases. + Fusible inserts. Each consumable is critical in respect to: + Specification/supplier requirements. * Condition. + Storage/handling. + Treatment (baking) if applicable. Gas shielded are welding filler wires The electrode must be carefully selected with regard to the parent material to be welded and the process variation to be employed. The electrode wire is related to its strength requirements of the deposited weld metal, as well as to the composition. The following factors govern the selection of the electrode. . Metal to be welded . Thickness of the joint. : Surface conditions. . Specification or service requirements Many specification and standards exist for filler wires in shielded gas arc welding for example: BS 2901, EN 440 and AWS A5.18 The requirements in all cases are tnat the wire shell be free form contamination such as grease, corrosion or other foreign matter, which would adversely affect the weld quality. In the case of some mig/mag and saw wires they are often copper coated to protect the wire from corrosion. The copper coating also improves the electrical pick-up via the contact tube (the copper content generally shall not exceed 0.35%). WIS 5 Issue 1. Date: 20/02/02 Section 14-120 40 & Certification Functions of fluxg The functions of a flux can be summarised as follows: _ + To provide a shielding gas protecting the weld pool from atmospheric: contamination, oxygen and nitrogen mainly which may cause inclusions and reduce weld zone ductility. + To provide a slag which gives additional shielding to the weld pool and assists: in manipulation during welding. The slag also provides a thermal blanket, which slows down the cooling rate of the weld improving the mechanical and metallurgical structure of the weld zone. + To improve the physical properties of the ares The coating additives improve arc stability, arc initiation and ease of use. + To introduce weld metal alloys, iron powder, deoxidants etc. thereby improving metallurgical properties; lowering oxygen and nitrogen levels. Iron Powder may also be added to increase deposition rates/electrode efficiency, MMA electrode constituents + Slag former. + Fluxing agents * Arc stabilisers * Gas former + Deoxidises + Binders (if required) + Alloying elements. + Iron powder in certain cases as to improve deposition. Flux types Acidic:'are composed mainly of oxides and silicates, which produce high oxygen content in the weld pool. They produce welds of a very smooth profile with a tendency for concavity. The slag has a porous or honeycomb structure, which is easy to detach (friable). The welds do tend to have high ductility but low strength and a high tendency to solidification and hydrogen cracking Cellulose: this coating has large quantities of organic materials containing cellulose, flour and wood pulp being the most common constituents. The organic compounds decompose in the arc and produce large volumes of shielding gas- containing hydrogen, which replaces the air in the arc column. The Presence of hydrogen increases the voltage across the arc and makes it more penetrating. For a give current the depth of penetration with cellulose electrodes is about 70% greater than other electrode types. Because most of the flux decomposes, the resulting slag layer is thin producing a rapid bum off rate and a fast freezing weld pool; this makes the electrodes suitable for all positional work including vertical down and overhead work. One of the main application areas of cellulose electrodes is the welding of pipelines and storage tanks. The completed welds tend to have a rough appearance with coarse uneven ripples; the spatter content is higher than that achieved with other electrode types. The mechanical properties WIS 5 Issue 1. Date: 20/02/02 Section 14-220 30 40 TWI ra aa of these electrode types are good but the hydrogen content is very high this restricts them being used on high tensile strength materials. Cellulose electrodes are designed to hold between 4-7% moisture, they must be kept dry but never baked. The flux contains the following: + Cellulose (mainly wood pulp and flour) — gas former. High in hydrogen, which increases the arc voltage + Titanium dioxide ~ slag former, A minor addition only not enough to affect ionization. + Sodium silicate ~ main ionizer. Br cla ig & Certification Rutilé: electrodes of this type are used mainly on general-purpose work such as” mild stee! fabrications, low-pressure work and support structures. Rutile electrodes are based on titanium oxide. This compound has good slag-forming properties and produces a stable easy to use arc. The profiles are good and the slag is easy detachable due to the medium oxygen content in the weld pool Electrodes of this type can be used in all positions but not often vertical down. It is not easy to achieve high tensile strength welds with a rutile flux this is due to the moisture content within the flux, which is required to keep the flux intact. If this moisture is driven off, the binding of the flux will suffer. The hydrogen content of the weld cannot be controlled to @ low level suitable for high strength materials, generally in the order of 25 to 30mi/100g. The flux should be kept dry but never baked. The flux contains the following Ave stibildne + Titanium oxide (Futile) — slag former and seeendary-ionizes, + Clay —binding-egent. Slag aX pegrove vixconity + Sodium silicate —-mainionizer. Binela— Basic:-electrodes of this type contain mainly calcium compounds such as calcium carbonate, Basic electrodes were designed to produce a weld with low hydrogens content suitable to weld high tensile materials. Prior to them being used they may be baked to over 300°C for over one hour but this is dependent upon the make and manufacturé-of the electrode (as to manufacture instructions). When baked and used in the correct condition the hydrogen content in the weld can be reduced to between 10 and 15 mi/100g. At this level the risk of cracking in high tensile steels is minimised. Electrodes, which are treated in this way, are referred to as hydrogen controlled. Other typical precautions for basic electrodes are heated storage areas, quivers for on site use and the electrodes should be used with a short arc gap and minimum weave this makes manipulation difficult. Therefore basic electrodes generally require a higher degree of welder skill when compared to other types. The mechanical properties of basic electrodes are high, and it is possible to produce welds, which match almost all commercially produced carbon — manganese and low alloy steels. The oxygen content of the slag is low this tends to produce surface profiles that are convex. The slag is difficult o detach (not friable). Additions of iron powder may be made to the flux to increase deposition rates by over 160%. Calan Con Umestona) plantect Se Se] WIS 5 Issuc 1. Date: 20/02/02 Section 14-3 Kamin abt > Ree S labile20 30 40 TWI training & Certification A Mass of metal deposited sq 994 Electrode efficiency = Wass of core wire melted The flux contains the following + Calcium carbonate (Limestone) ~ gas former (mainly CO.) and secondary ionizer. + Fluorspar — slag former (higher quality when compared with titanium dioxide). + Sodium silicate or potassium silicate ~ main ionizer. BS EN 499 : 1994" E 50 4 2Ni B 7 2 H10 Covered electrode a Yield strength (N/mm?) Tensile strength (N/mm?) Elongation Toughness Chemical composition Covering Weld metal recovery and current type Welding position Hydrogen content WIS 5 Issue 1, Date: 20/02/02 Section 14-420 30 40 TWI ts ed BS EN 499: 1995;- Covered electrodes for manual metal arc wel: alloy and fine grain steels Classities electrodes and designates a flux covering code Example coding E 46 3 1NiB 5 4 HS 1. The letter E. Symbol for the product/process. A flux coated electrode for manual metal arc welding. 2. The number 46. Symbol for strength and elongation of all weld metal. 46 relates to a tensile strength 530 — 680 N/mm? range, minimum yield value 460 N/mm? and a minimum elongation value of 20%. 3. The number 3. Symbol for impact properties of the all weld metal. 3 indicate at -30°C the average impact value will be 47 J 4. The letters 1Ni. Symbol for the chemical composition of the all weld metal. 5. The letter B. Symbol for the flux covering. B indicates a basic flux, R indicates a tutile flux and C indicates a cellulose flux 6. The number 5. Symbol for weld metal recovery and current type. The recovery relates basically to the amount of iron powder present in the flux. 7. The number 4, Symbol for welding position. 4 indicate the specific welding position the electrode can be used in. 8. H5. Symbol for hydrogen content of all weld metal in ml per 100 g of weld metal deposited. E35 Minimum yield strength 355N/mm? Tensile strength 440-570N/mm2 Elongation 22% E38 Minimum yield strength 380N/mm? Tensile strength 470-600N/mm2 Elongation 20% : £42 Minimum yield strength 420N/mm? Tensile strength 500-640N/mm2 Elongation 20% £46 Minimum yield strength 460N/mm? Tensile strength 530-680N/imm2 Elongation 20% £50 Minimum yield strength S0ON/mm* Tensile strength 560-720N/imm2 Elongation 18% WIS 5 Issue 1. Date: 20/02/02 Section 14-5TWI training & certincation | ia AWS electrode coding A5.1/A5.5 A8.1® Specification for carbon steel electrodes for shielded metal arc we 5.5 = Specification for carbon steel electrodes for low alloy steel covere welding electrodes? Example coding E70 18 M ie Electrode. 2. 70 70,000psi specified minimum ultimate tensile strength. 34 Welding position suitable. 4.8 Flux type and electrical characteristics wo 5. Moisture controlled Examples electrode types Cellulose: £6010, £6011, E7010, £8010 Rutile: E5012, 6012, £6013, £6014 Basic: £6016, E7017, £7018, £8018, £9018. AWS A5.1/5 E 70 20 Covered electrode 146-2 Pst ec IN lowe IMpa Tensile strength (p.s.i. Welding position 30 - Flux coveringLWA raining & certincation ia Questions Welding consumables Qu Why are basic electrodes commonly used on materials with high tensile strength, and what controls are required when using basic electrodes: qu E 80 1 8 M: from what document is the example classification taken from and briefly discuss the individual parts of the classification. Qu3 Why are cellulose electrodes commonly used on pipelines? Qu4 Give two more alternative terms given to a fusible insert and briefly discuss its purpose in welding Qus Explain the following parts of an electrode code E42 1NiB42H10 WIS 5 Issue I Date: 20/0202 quia20 30 40 1g & Certification, Steel Weld Metallurgy Mechanical properties of metals « Plasticity?may be defined as the ease with which a metal may be bent or molded into a given shape. At ordinary temperatures, lead is one of the most plastic of metals, The plasticity usually increases as temperature rises. Iron and steel are. difficult to bend and shape when cold, but it becomes easy to do this when heated above red heat. Wrought iron for example sometimes breaks when we attempt to. bend it hot (called hot shortness), this is due to the impurities within it, and thus increases of temperature is not always accompanied by an increase in plasticity Brittleness: the tendency of a metal to break suddenly without plastic deformation. Brittleness is essentially the opposite of plasticity and denotes a lack of elasticity. Cast iron and high carbon steels are examples of brittle metals. Most metals when heated become less brittle. Brittle metals require care when welding, due to the lack of elasticity and their tendency to cracking Malleability: is the property possessed by a metal of becoming permanently flattened or stretched by hammering or rolling. The more malleable a metal is, the thinner the sheets into which it can be hammered or rolled. Gold is the most malleable metal, copper is also very malleable, except around its melting point. Metals such as iron and steel become malleable as the temperature rises and are readily hammered and forged. Duetility: is the ability of a metal to be drawn out into wire. Like malleability this property enables a metal to be deformed mechanically. Metals are usually more duetile when cold, and thus wire drawing and tube drawing are often done when cold, but not always. Creep: this is the term applied to the gradual change in dimensions, which occurs when a load is applied to a specimen for a long period of time. In general it is found that a specimen shows greater extension for a given load over a long period than for a short period and may fracture at a load much less than its usual tensile load. The effect of creep is greater at elevated temperatures and certain ‘materials usually containing molybdenum are designed to resist creep “creep resistant steels". Creep resistant steels have a high resistance to elongation when stress is applied for long periods of time at either ordinary or elevated temperatures. Hardness: is the property possessed by a metal to resist scratching or indentation. It is measured on various scales, the most common of which are, the Brinell Rockwell and Vickers. Hardness decreases with rise in temperature. The addition of carbon to steel greatly increases its hardness after heat treatment, and the operations of rolling, drawing, pressing and hammering greatly affect it. WIS 5 Issue 1, Date 20/02/02 Section 4—420 30 Td ‘Training & Certification Table of comparative hardness Material Brine Vickers Lead 6 6 ‘Aluminum (pure) 19-20 20-24 | Zinc 45 46 Copper (casi) “40-45 “42-48 Mild steel 400-120 108-130 Stainless steel 150-165 160-180 Cast iron, 150-250. 460-265, Fatigue: |s the tendency of a metal to fail under a rapidly alternating load, that is a load which acts first in one direction, decrease to zero and the rises to a maximum in the opposite direction, this cycle of reversals being repeated a very great number of times. Many factors, such as the frequency of the applied stress, temperature, internal stresses, variation in section and sharp corners leading to stress concentration, affect the fatigue limit. Elasticity: is the ability of a metal to return to its original shape upon removal of the applied load. If the load applied is large enough, the resistance of the atoms will be overcome and they will move and take up new positions in the lattice. If the load is now removed the metal will no longer return to its original shape, it has become permanently distorted. The point at which a material ceases to be elastic and becomes permanently distorted is termed the yield point. The material is now said to have undergone piastic deformation or flow. Many elements may be present in steel, some of which are added or reduced to certain levels to produce specific properties, for example: Alloy steels Many elements may be present in steel, some of which may be added or reduced ‘0 produce specific properties, An alloyed steel is a steel which contains one or more other elements such as: + Carbon (C): The key element in steels. Has the major influence on strength toughness, ductility and hardness. + Nickel! (Ni): One of the most important alloying elements, nickel is widely used in stainless steel and heat resisting steels. The addition of nickel increases the strength and toughness: + Chromium (Cr): This element has the opposite effect from nickel on steel! because it increases the hardness and strength but reduces the ductility, Chromium also tends to refine the grain structure of steel, thereby increasing its toughness, also adding an increase to the steels resistance to corrosion ‘+ Moloybdenum (Mo): A relative expensive alloying element which has a strong effect on hardenabilty, and a high creep strength at high temperatures. Steels containing molybdenum are less susceptible to temper brittleness than other alloy steels, * Copper (Cu): Used in amounts up to 1%, its main value is to assist in the resistance of steel to atmospheric corrosion. WIS 5 Issue 1. Date 20/02/02 Section 4-220 30 ing & Certification ta Tei * Manganese (Mn): Used extensively as an alloying element in steel and has considerable effect on its structure. Manganese has a similar effect to carbon ‘on such properties as tensile strength, hardness, ductility and toughness. Manganese is added to most steels as a deoxidiser, and is used to combine with sulphur to prevent hot shortness * Silicon (Si): Small amounts of silicon are normally present in steel from 0.1% to 0.35%. In these quantities silicon does not directly affect the strength of the metal, its main function is as a deoxidiser. + Tungsten (W): In some respects the effects of tungsten is the same or similar to that of molybdenum added to increase hardness and toughness at elevated temperatures and added resistance to abrasion weer. * Vanadium (V): Used to refine the grain structure and increase the hardenability of steels, it may also be used as a deoxidiser. ‘+ Aluminium (Al): tis added to steel during the steel maufacturing process as a grain refiner itis also a deoxidiser. Most steel elements when present in undesirable amounts may be considered as. impurities. Sulphur and phosphorus in particular, are usually kept below levels of ~ 0.04%, because sulphur promotes hot shortness and phosphorus promotes cold shortness, Hot shortness: The susceptibility of a material to crack during hot working. Cold shortness: The susceptibility of a material to crack during cold worl Grain structures of steel The grain structure of a material will influence its weldability, its mechanical properties and in-service performance. The type and number of grain structures Present in a material will be primarily influenced by three factors: ‘+ The elements in the material + The temperature reached during welding andlor post-weld heat treatment + The rate of cooling Single or muttiple grain structures may be present in a material in its final state, The essential difference between ordinary steel and pure iron is the amount of carbon in the former, which reduces the ductility but increases the strength and the susceptibility to hardening when rapidly cooled from elevated temperatures Pure iron is only pure in the sense that it contains no carbon, but sometimes contains very small quantities of impurities such as sulphur, phosphorous, oxygen and nitrogen, dissolved in the solid metal. The structure is built up of a number of crystals of the same composition, given the name of ferrite. ‘WIS 5 Issue 1. Date 20/02/02 Section 4-320 30 TWI training & certincation Austenite: is the high temperature form of carbon, carbon and manganese and low alloy steels, which exists above 723° C. The temperature at which the material becomes fully austenitic depends primarily upon the carbon content, e.g. low carbon steel < 0.1% carbon — over 910° C; >0.8% carbon about 730°C. Very slow cooling produces very soft steels, high ductility but low tensile strength; very fast cooling produces very hard and brittle steels, low ductility with an increase risk of cracking but with high tensile strength depending on the carbon content and thickness of the steel. Ferrite: Is essentially pure iron at room temperature, it is only pure iron in the sense that in contains no carbon. This structure is formed from the austenite region by holding at a temperature which depends on the carbon content of the steel, €.g. 910°C for low carbon steel. Ferrite is very soft and ductile and has low tensile strength but good machining properties. Pearlite: Forms from the austenite region under slow cooling and consists of ferrite and cementite, it is harder than ferrite because of the layers of cementite it contains. Pearlite is the most frequently encounted grain structure in a constructional steel Bainite: forms from the austenite region when the cooling rate is too fast for perlite to form, it is harder and usually tougher than perlite. Bainite often forms in the h.a.z. area of carbon or carbon manganese steels. Martensite: is very hard and brittle grain structure but can be tempered in order to improve toughness. It is formed from the austenite region by quenching or very fast cooling. This grain structure can only be formed in plain steels when sufficient carbon exists, unless specifically designed into steel; the presence of martinsite should be avoided. WIS 5 Issue 1, Date 20/02/02 Section 4-420 30 40 bu ‘Training & Certification The heat affected zone During welding using a fusion welding process there is a huge temperature difference between the weld and parent material. Because of this temperature difference, the material immediately adjacent to the weld undergoes microstructure changes. This area, which lies between the fusion boundary and the unaffected parent material, is called the heat affected zone (h.az.) The extent of change in microstructure will depend on the following, 1, Material composition, especially the carbon contents. 2. The cooling rate. The faster the cooling rate the harder the heat affected zone, especially if the carbon equivalent of the steel is high. 3. Heat input. The higher the heat input or are energy the wider the heat affected zone. Are energy (KJ/mm) = Volts x amps Travel speed (mm/s) x 1000 The h.a.z of a fusion weld on steel consists of upto four separate regions of microstructure; the actual condition will be dependant upon the alloying elements present and the thermal conditions applied during welding. The following grain structures starting from the area immediately adjacent to the weld are typically present on 0.15% carbon steel. 1. A coarse grain region (heated between 1100°C and melting point) 2. Aggrain refined region (900 to 1100°C). 3. A region of partial transformation (750 to 900°C). 4. A region of spheroidization (just below 750°C). On C-Mn and low alloy steels the h.a.z of the weld tends to be more brittle than the actual weld. The h.a.z are is therefore more prone to cracking especially when hydrogen induced, although it must be noted that the tensile strength of the h.az is normally high in comparison with the weld and parent material. Unfortunately, if a fusion welding process is being used the h.a.z cannot be eliminated, although it can be controlled. Carbon equivalent The carbon equivalent (CE) of steel primarily relates to its hardenabiltiy. If steel has a relatively high CE it will be more susceptible to hardening in the heat affected zones of any weld made, in comparison with welds made on steels of a low CE. Hardenabilily affects weldability, therefore materials of high CE are considered more difficult to weld, The CE of a given material depends on its alloying elements; typical elements in carbon manganese steel are as follows. WIS 5 Issue 1. Date 20/02/02 Section 4-520 30 40 TWH training & Cert ay + Iron (Fe) + Silicon (S) * Carbon (C) © Titanium (Ti) ‘Manganese (Mn) + Niobium (Nb) * Chromium (C) + Aluminium (Al) + Vanadium (V) + Tin (Sn) + Molybdenum (Mo) + Sulphur (S) + Nickel (NN) + Phosphorus (P) The CE of steel is usually calculated from the CE formula (given in EN 1011) CE=C+Mn , Cr+Mo+V , Cutni 6 5 6 = 0.1% Carbon has the same effect on hardenability compared to 0.6% Mn, therefore the manganese content is divided by 6 because one part manganese has one sixth of the effect on hardenability compared to one part carbon Preheat Preheat is the application of heat to a joint prior to welding. Preheat is usually applied by a gas torch or induction system, Preheat is an expensive operation and therefore only carried out when necessary, i.e. if there is a significant chance that an adverse metallurgical structures and/or cracks could occur. Preheat on steel pipe and many steel structures are arrived by taking into consideration the following: + The are energy. The hydrogen scale requirements + Carbon equivalent * Combined material thickness, Example of combined thickness Joint a Joint b Combined thickness = 1.1 +12 Combined thickness = £1 41.2413 WIS 5 Issue 1, Date 20/02/02 Section 4-61g & Certification a Trai Thicker materials usually require more preheat than thinner materials, however, for a given CE and are energy, the preheat temperature is likely to be the same for wall thickness up to 20 mm. ‘A welding inspector would normally find the preheat temperatures from the applicable welding procedure. Conditions for welding steels with defined carbon equivalents 1 200, 100 20 |. 60 40 20 ° 00 05 40 15 20 25 30 35 40 45 50 56 Key 2 4 Combined thickness, mm, 2 Heat input, Kien '3 Minimum preheating temperature, °C 4 Scale 5 To be used for carbon equivalent not exceeding WIS 5 Issue 1. Date 20/02/02 Section 4~720 30 40 ep ‘Training & Certification Advantages of preheat 1. Slows down the cooling rate of the weld and h.a.z, which reduces the risk of hardening 2. Allow absorbed hydrogen a better opportunity of diffusing out, thereby reducing the risk of cracking. 3. Removes the moisture in the region of the preparation. 4, Improves overall fusion characteristics, 5. Lowers stresses between the weld metal and parent material by ensuring a more uniform expansion and contraction. Basically the application of preheat improves overall weldability. It must be also noted that if tack welding is to be carried out prior to welding, the tack welds should also be preheated, Preheat temperatures may be measured by the use of temperature indicating crayons (Tempil sticks ®) or thermocouples which should have a valid calibration certificate. The type and method of taking temperature reading should be stated in the applicable specification for the work being carried out. Preheat temperatures are measured at intervals along or around the joint to be welded. The number of measurements taken must allow the inspector to be confident that the required temperature has been reached over the full area to be welded. EN 1011 states that the preheat temperature must be maintained at least 50 mm back form the joint faces. The preheat temperature should be taken immediately prior to welding. If a gas heat source is been used, the temperature should be taken from the opposite surface to which the heat source is being applied. If this is not possible sufficient time must be allowed for the temperature to equalize throughout the thickness of the components being welded, otherwise only the surface temperature will be measured. Time lapses may vary depending on specification requirements. EN 1011 states 2 minutes for a 25-mm wall thickness and a further 1-minute for every 25-mm of wall thickness. If preheat is being applied and tack welding is being carried out prior to the main welding then it should be noted that the tack welds should also be preheated. WIS 5 Issue 1. Date 20/02/02 Section 4-8ie Training & Certification Tempilstick® are available in the following temperatures arr CS CT 100 38 325 163 | 575 302 | 1200 649 | 2050 1421 10339 as1 165 | 600 ae | 1250 677 | 2100 1149 10544 338 70 | 625 929 | 1300 704 | 2450 ti77, 10943 ees 473, | 650343 | t50 732 | 2200 204 1345 350 77 | 700 371 | s400 760 | 2980 i232 11348 263 184 | 750300 | 1425 774 | 2300 1260 125 82 37s 191 | e00 427} 1450 78 | 2350 4288 155, aes 103 | 850 45¢ | 1480 0s | 2400 1316 13859 400 204 | 00 482 | 1500 815 | 2450 i349 14462 413212 | 9x2 soo | asso 849 | 2500 4371 15068. 425 218 | 950 510 | i600 a7 1369 | 438 ms | 77 525 | $650 809 16273 450 232 | 1000 $38 | 1700 27 16276 463230 | 1022 550 | 4750 a8 175 78 | 475245 | 1050 566 | 1800 382 wz 03 | 488 253 | 1100 503. | 1850 toto 18887 00 260 | 1150 621 | 1900 1038 19490 525274 19501056 20093, 550288 20001093 WIS 5 Issue I. Date 20/02/02 Section 4-9iy “Training & Certification Inter-pass temperature The inter-pass temperature is the temperature of the joint during welding and between passes. It is often specified that the minimum inter-pass temperature ‘must not drop below the minimum preheat temperature. The actual requirements depend upon the requirements of the applicable specification. WIS 5 Issue I, Date 20/02/02 Section 4-10Td ‘Training & Certitieation Questions Steel weld metallurgy qui List the three factors that will influence the type and number of grain structures present in a material. Tle elame uz. What is the ere enbray in kilmm using 30 volts, 150 amps and a travel speed of 8 inches per minute? Boy t¢ 2 Kom Qu3. When and were would the welding inspector measure the pre-heat temperature if gas flames have been used for the pre-heat application, also include any applicable precautions that may require checking. Qu List four advantages of the use of pre-heal prior to welding: Car Gig Qoaat thks, Qus. Discuss the properties of the following elements, and their influences on carbon steels. a) Carbon. ren? . J ar sae ecole b) Manganese. ¢) Aluminum d) Molybdenum. ee ees es » ©) Nickel WIS 5 Issue 1 Date: 2002/02 auswae ‘Training & Certification Questions Qui uz. Qu, Qua. Qus. Steel weld metallurgy List the three factors that will influence the type and number of grain structures present in a material. What is the arc enérgy in kJ/mm using 30 volts, 150 amps and a travel speed of 8 inches per minute? When and were would the welding inspector measure the pre-heat temperature if gas flames have been used for the pre-heat application, also include any applicable precautions that may require checking List four advantages of the use of pre-heat prior to welding: Discuss the properties of the following elements, and their influences on carbon steels. a) Carbon, b) Manganese ¢) Aluminum. 4) Molybdenum. €) Nickel WIS 5 Issue 1 Date: 20/02/02 usThird and fourth] oo 7 7 f current aon Welding position| ee ae Type of covering and slag 10+ F.VOH,H — {d.c. electrode positive High cellulose + FV.OHH fa.c., or d.c. electrode positive High cellulose 12+ F.V,0H,H a ‘ae Positive | igh titania, viscous slag 13+ F.V,OH,H eS oon High titania, fluid slag 144+ F,V.OH,H ae ie Positive tow iron powder, titania 15 FV,OH,H — [d.c. electrode positive *Hydrogen controlled, basic 16+ F,V,OH,H — a.c. or dc. electrode positive [*Hydrogen controlled, basic *Hydrogen controlled, 18+ F.VOH.H Jac. or d.c. electrode positive basic, low iron powder 20 FH Pe Oe te cetrode postive ah ion oxide 24+ F.Hsfilet f2-6 OF Ue electrode postive it icon powder, titania T+ F.H-fillet | o oe ea Positive | igh iron powder, iron oxide 7 *Hydrogen controlled, high 28 FH-filletJa.c., or d.c. electrode positive ‘ron powder, basic 45 F.V-down OH.H|d.c. electrode positive *Hydrogen controlled, basic | 46+ F.V-down, OH,H]a.c., or d.c. electrode positive |* Hydrogen controlled, basic | z tive | Hydrogen controlled, 48+ F.V-down, OH.H fa.c.,-or dic. electrode positive basic, low iron powder As specified by e ‘As described by 99 manufacturer |S Specified by manufacturer manufacturer NOTE: The abbreviat positions: F = Flat, V = Vertical, V-down = Horizontal fillet. ions, F, V, V-down, OH,H, and H-fillet indicate the following welding Vertical down, OH = Overhead, H = Horizontal, H-fillet =1. WELDING INSPECTION STEELS - COURSE REF. WIS 5 END OF CGURSE MULTIPLE CHOICE PAPER (MCQ.002) Name: .. Answer all questions. S499 Part Il communicates by the use of symbols the type of joint preparation to be used. Listed below are four symbols; which of these indicates the depth of penetration of the weld required on the joint? \e c D wk ek ks Which of the following symbols would indicate that a weld has to be finished flush on the ‘other’ side of the weld? A Vv clotterk Liar indveak sr Copprsldsida 4D aa What two functions in arc welding must be in equilibrium to enable a stable arc to be established? . Ave Voltage Current Wire/Electrode feed rate Metal burn-off rate logoIn MMA welding, what parameter is used for the control of penetration into the base material? B® Voltage B *" Welding Speed c Iron Powders in the coating \ 2 Current In the welding of a butt joint made from one side, which of the following controls the profile of the root bead? ® Root Face B Bevel Angle \ © Root Gap D None of the above What type of power source characteristic is required for manual welding? A Constant Voltage B Flat Characteristic \ i) Drooping Characteristic D Motor Generator Which one of the following destructive tests would indicate the toughness of weld metal/parent metal - haz. A Macro - 8 Nick Break c Hardness V (e) Charpy Vee Notch8. Degreasing components are essential for quality welding but some agents may A Cause Corrosion Problems 8 *" Give off Phosgene Gas © Leave Residues Cc \ eo) All of the Above 9. Which of the following chemical elements has the greater effect on the hardenability of a steel plate? A Molybdenum 8 Chromium Titanium c 1 @) Carbon 10. In MAG/CO, welding, which parameters give the greatest control of weld appearance during dip transfer or short circuiting welding? A Wire stick-out length B Amperage c Wire feed speed Vv @) Inductance 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 HY position? 3S Fluid Viscous Cc "None of the above wy Semi fluid12, 13. 14, 15. The weld metal deposit of manual metal arc electrodes achieves its mechanical strength through? The Core Wire A \ Gy ~ The Flux Coating Cc Iron powders with the flux coating What constituent is needed in a coating of an electrode to prevent the formation of porosity in welding of a rimming steel? A fron Powders &) Calcium Fiuoride Ve Silicon D Calcium Carbonate Welds made with high heat inputs show a reduction in one of the following properties? A Ductility \ ) Townes c Fatigue Strength D Mechanical Strength In the welding of austenitic pipework, the bore is usually purged with Ar to 2 A Prevent formation of porosity in the weld. B Prevent burn-through in the root run. \ >) Prevent oxidation of the root bead D _ Eliminate the formation of H,.16. 17. 18. 19, In X-ray work, the quality of the radiogrpahic negative is assessed by the ? LA Density of the Film Vy lavas c KVA available D Stand-off Distance A steel described as QT will have improved tensile properties because it has ? A Had control of chemical composition \ Been heat-treated c Been quality tested D Been vacuum melted Which one of the following type of steels would give rise to the formation of porosity when autogenously welded with an arc process? A Fully killed steel B Semi killed steel \ &) Rimming steel D Fine grained stee! In submerged arc welding, the use of excessively high voltage would result In? A Insufficient flux melting \ 8 Excessive flux melting ™ Slag removal difficulties oD Spatter20. The use of cellulosic electrodes is often made when welding the root pass of pipes in the field. This is because ? A VO Hydrogen control is needed *~ Iron powders in the electrode Higher arc voltage can be obtained Shorter arc length can be achieved 21. 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 ? A V® Cc D Cracking in the HAZ The formation of chromium carbides Cracking in the weld metal Distortion 22, Submerged are fluxes can be supplied in two forms; these are ? A B Ve Sintered and agitated Agitated and fused Crushed and agglomerated Fused and agglomerated 23. Ina steel which has improved creep properties at elevated temperature, which one of the following elements helps in this improvement ? # ® Vc Tungsten Manganese Molybdenum Carbon24, 25. 26. 27. Welding a steel plate of a CE of .45 would require preheating to ? A re) Cc D Prevent the formation of sulphides ~ Prevent hardening in the HAZ Prevent the formation of carbides To improve mechanical properties in the weld. Which one of the following processes uses the "keyholing" system of fusion? A Vo D Friction welding . Diffusion bonding Electron beam welding Autogenous TIG welding In friction welding, is the metal at the interface in the ? A a) Liquid state Solid state Plastic state Elastic state Welding procedures may require welds to be deposited ata controlled rate heat input. High heat inputs would ? A Ves Have poor profile Have larger grain size Have high hardness in the HAZ Have low elongation propertiesIn a tensile test, a brittle material would be indicated if the fracture surface 2 Shows a reduction in size ~ |S flat and featureless Breaks in the weld metal Breaks in the parent material What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a weld? 28. A c D 29. A B ko Nick break Side bend test Charpy impact Macro test 30. In submerged are welding, excessive are voltage may cause ? A 2 Cc D Excessive penetration Change in weld metal composition Narrow weld width Excessive bead profile.: 23 766% LW cerncation Tsing 3o - 7 Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-3) Name: ARTHUR, BeAkemore Answer all questions 1. The likelihood of a brittle fracture in steels will increase with a. The formation of a fine grain structure. LD) Areduction in-service temperature to sub-zero conditions c. A slow cooling rate. d. All of the above. 2. Hydrogen cracking ina ea So is most likely to occur when welding: @ Carbon manganese steels. b. Austenilic stainless steel. ©. Micro alloyed steel (HSLA). d. Low carbon steel. 3. reheating for are welding applies to: ——? 2 Assembly and tack welding only b. Joint over 25 mm thick only. x A\la-d ‘Assembly welding only. oe 4. When using the MMA welding process only e Both 2 and b. he toughness vaive of 4, Which of the following destructive tests would ingi the weld metal/parent metal and HAZ? a. Macro. b. Nick break, Tensile. oe ea) Charpy Vee notch,TW certincation & Training 5. What constituent is needed in a coating of an electrode to prevent the formation of porosity when welding rimming steel? a Iron powder. Potassium silicate. b. VO Silicon d. Calcium carbonate. 6. Welds made with high heat inputs show 2 reduction in one of the following - properties? 2 Duetility. b..) Toughness. c. Elongation. d. Penetration: 7. Which of the following steel types would give rise to the formation of porosity when autogenously welded with an arc welding process a. Fully killed steel. b. Semi killed steel. Va Rimming steel. d. Balanced steel. 5 Which of the following elements, which may be added to steel, has the greatest affect on creep strength. - : a. Tungsten. b. Manganese. . Carbon, * Molybdenum.TLWI certification & Training Wi 9. The HAZ associated with 2 fusion weld: xX® — ra e Can not be avoided. Usually has the highest tensile strength Is usually martensitic. Both a and b. Allof the above. 10. What four eriteria are necessary to produce hydrogen induced cold cracking? a. VO) d. Hydrogen, moisture, martensitic grain structure and heat Hydrogen, poor weld profiles, temperatures above 200°C and a slow cooling rate. Hydrogen, a grain structure susceptible to cracking, stress anda temperature below 200°C, Hydrogen, existing weld defects, stress and a grain structure susceptible to cracking. 11. A carbon equivalent (CE) of 0.5%: a 's high for carbon manganese steel and may require a preheat over 100°C 's generally significant for carbon for manganese steels and is certainly Not to be taken into consideration for preheat temperatures. Is high for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking 7 !s catculated from the heat input formula ‘martensitic grain structure what would you expect to increase? Duetility Hardness. Toughness. a Alll of the above.TWI certinication & Training We 13. What do you understand by the term minimum interpass temperature? a. Minimum post weld heat treatment applied to a weld b. Minimum stress relief temperature The lowest temperatre to be used during preheat c v@) The lowest temperature allowed during welding and between weld passes. Which of the following heat treatments on steel cools down in air from the austenite region? ——Pa. __Normaiising, b. Annealing rE) Tempering d. Stress relieving, 14. 15. What is the purpose of microscopic examination of a weld? a. To determine the number and type of defects present, AO) To determine the grain size. c. To determine the strength of the weld. ——4. Both a and. @. All of the above. 16. \Which of the following units could a tensile specimen be measured in? Pounds per square inch. 9 b. Newton per square inches. - : asia wantne frscus - fore bnswar Joules. b ¢ w ) + Both a and b.LW certitication & Training 17. Assuming that the welding process, material thickness, carbon equivalent and the welding parameters to be the same, which of the following joint types would normally require the highest preheat temperature a Edge joint. b. Lap joint. ¢c. Butt joint (single-V), MG) Tee joint (fillet welded), 18. Austenitic stainless steels are more susceptible to distortion when compared to ferritic steels this is because: @ High coefficient, low thermal conductivity. b. High coefficient, high thermal conductivity. c. Low coefficient, high thermal conductivity. 4. Low coefficient, low thermal conductivity, 19. Which of the following will most likely require the preheat temperature to be increased? uM 3) An Increase in travel speed. b. A reduction in material thickness c An increase in electrode diameter, gd, None of the above 20. Which of the following properties may be applicable to a carbon steel'weld (CE 0.48) welded without preheat?

To help prevent tungsten inclusions during weldTWI cevtiiesion train He 17. When considering thermal cutting local hardening can bs reduced by: 2. Increasing the cutting speed The use of propane as a fuel gas. b. \ & Pre heating the material to be cut. 4. All of the above 18. _ Ina semi-automatic welding process, which of the follov..ng shielding gas/gas mixtures would normally give the deepest penetration or steel?_ Ma a. 100% argon. ® 100% COz. c. 75% argon + 25% CO2, d. All of the above would give the same depth in peretration. 19. Ina MMA welding process, which of the following statements are false? 2. Anarc gap, which remains almost constant even if as usual the welder varies the position of the electrode. DB Avoltage, which remains almost constant even if as usual the welder, varies the arc gap. c A current, which remains almost constant even if 2s usual the welder, varies the arc gap. Vd Aandb. e All of the above. 20. Which of the following welding process, after the weld is completed normally fequires a post weld heat treatment to restore toughness values VG ESW, bo = MMA. c MAG. d. Ak completed welds require @ post heat trezimen: “egarcless of welding processTWI certitication & train 21 Which weldin. b. © a. 22. Which \® x of the following current types would you expect Ic be used for the ig of aluminium with the TIG welding process? OC -ve, OC +ve AC All of the above. of the following statements is false? In the MMA welding process electrode DC + produces a deep narrow weld pool, which is fast freezing. OC electrode positive is used for the MAG welding of steel plate. The word calcium carbonate means limestone All of the above 23. When considering hydrogen, which of the following welding process would produce the lowest levels in the completed weld (under controlled conditions) ZS MMA. SAW. TIG. FCAW. 24. Pre heat prior to the welding of a carbon steel butt weld: a. b. Must always be carried out. 's always carried out using a gas flame Need not be carried out if post weld heat treatmer- is to follow None of the above.ation & Training TWI ce A 25. _ In steel the element with the greziest effect on hardne: a. Chromium, b. Manganese. Vy @ carbon. d. Nickel. 26. For a given voltage and current settings on a MMA welding plant, when the arc length is shortened, which of the following will be mest affected. OY The current will increase. b. The current will decrease. \ © The voltage will decrease. d. The voltage will increase. 27. — Which of the following best describes a semi-automatic welding process? The welder is responsible for the maintaining the are gap and travel speed. a Vv &) The welder is responsible for travel speed only; arc gap is kept constant by the welding plant, ¢. Both travel speed and arc gap is controlled by the wvelding plant 6. All of the above. 28. _Whatis purpose of a rectifier in a welding sets electrical circuit? To keep the arc stable when using low current set:ags Vb. To convert AC current to DC current. ¢. To convert DC current to AC current, 6. To initiate the erc at start upTW certitcation & Training aa ) 29. When calibrating a mechanised MAG welding plant, whi applies (WFS = Wire feed speed)? io Check — WES, current, volts and wire diameter. Vo. Check — WFS, joint set-up, gas flow rate and WFS c. ich of the following Check — Gas flow rate, stick out length, WFS anc current d. Allof the above. 30. The main usage of the arc air process is: 7 @ The cutting of a weld preparation \ >), the removal of defective welds. ¢. For the cutting of non-ferrous materials only. d. For the cutting of ferrous materials only.ez 3% 30 n & Training Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-1) Name: Ae . BUR EMORE Answer all questions 1. Which of the following butt-weld preparations is usually the most susceptible to lack of sidewall fusion during the manual metal arc process? \ a Adouble-U butt. b. Asingle-V butt. A double-V butt. @ 'tis not normally a defect associated with the MMA welding process. 2. What is the leg length of a fillet weld? a. The distance from the toe to face. \ b. The distance from the root to face centre. {© The cistance from the root to the toe d. The distance from toe to toe. 3. What is the throat thickness of a fillet weld (equal leg lengths)? <3 The distance from the toe to the face. a Vay The distance from the root to the face centre, c. The distance from the root to the toe. d. The distance from toe to toe. 4. Lap joints contain: @) Fille: welds b. Corner joints ©. Buti-welds. 4. Single-bevel buttsTWI certifiati Training 5. Aduty not normally undertaken by a welding inspector is to: a. Ve Check the condition of the parent material. Check the condition of the consumables. Measure residual stress. Check calibration certificates. 6. Under most conditions, which of the following welding positions will deposit the most weld metal, oo Vertical down. Overhead. Horizontal-vertical. \ ) Flat (down hand) tes What meant by the term crater pipe: a. b. \@ Another term for concave root Another term given for a burn through. A type of gas pore, found in the weld crater. A shrinkage defect, found in the weld crater. 8, What is meant by the term weld junction? \S ©. d. ‘The area containing the HAZ and the weld metal. The weld metal and parent metal. The boundary between the fusion zone and the HAZ “The part of the weld, which has undergone metallu-aical changes due to the heat from welding of a fillet weld is primary controlled by: Leg length Thioat thickness. We'd thickness. All of the above.TWI certincaon & training Wh 10. A crater crack may also be termed: a Cold crack. b. Tearing. Fatigue crack ‘ \.@ starerack 11. Which of the following welding processes/technique is likely to be used for the repair welding of localised porosity in a butt weld? ie MMA, PG position b. Mechanised MAG. c. Submerged arc. d, All of the above. \V None of the above. 12. Which of the following welds would be considered in a situation where two Plates are to be joined that overlap (assume no external assess), A fillet weld. b. A single-bevel butt weld. Vee oA plug weld, 4. Asingle-U butt weld. 13. In the MMA welding process, which of the following is most likely to be caused by a welder with a poor technique? \ g Deep weld craters/crater cracks. b. Copper inclusions cc.» Hydrogen cracks d. Alfof the above.TWI cersitcation & Tra ie 14. Root concavity is caused by: a. Excessive back purge pressure and entrapped gas. ~) Excessive back purge pressure and very high heat inputs. c. Excessive root grinding and a slow travel speed. Vid Excessive root grinding and excessive back Purge pressure. 15. When inspecting a critical component, the toes of a weld must be. @. Always ground flush. 5. Must always overlap at least 1.5 mm onto the parent material Must always be inspected using @ crack detection method (MPI, DPI) None of the above can be selected ~ specification requirements unknown. 16. When carrying out visual inspection, the specification makes no mention of the requirements for visual inspection, in this situation what should you do? a. Carry out normal visual inspection. \ @) Seek advice from higher authority. . Carry out no visual inspection. 4. Re-write the requirements of the specification, 17. Under most circumstances, which of the following do you consider to be duties of a welding inspector? a The supervision of welders. b. Procedure writing \ () Qualifying welders d. _ Allof the above.TWI certiteation & training i 18. Which of the following is most likely to cause a burn through a. Root gap too small b. Travel speed too fast. \ ©) Root face too small d. Alll of the above. 19. In an arc welding process, which of the following is the correct term used for the amount of weld metal deposited per minute? a. Filling rate, \ Deposition rate. ©. Weld deposition. d. Weld duty cycle. 20. What is the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? a Heat affected zone. b. The weld zone. Fusion zone. All of the above terms may be used. ao 21. When carrying out visual inspection, which defect (5) is likely to be missed? a. Linear misalignment . b. Cap undercut. c. Porosity, \ gd.) Lack of fusion (inter run). 22. Cold lapping is another term for: VG Lack of fusion at the toe of a weld, b. Lack of fusion between weld metal and weld metal c Undercut al the toe of a weld, 4. Both a and b.TWI certiication & Training 23. Incomplete root penetration is most likely due to a. Welding speed too slow b. Welding current too high. | &® Root gap too small a. Electrode diameter too small 24. Crater cracks are caused mainly by: a. Excessively fast welding speeds \ b. Improper electrode angle — @) Hot shrinkage. Improper joint design. 25, On a single-V butt weld, the distance through the centre of the weld from root to face is called: a Reinforcement. b. Penetration. \ &) Throat thickness. d. None of the above. 26. — The throat thickness of a % inch fillet weld is? a. 27.5mm b. 24mm. \ ée) 13.5 mm. 6. 12.5mm. 27. The feed for pre-heat for steel will increase if The material thickness reduces. ‘\ b. Faster welding speeds ” The use of a larger welding electrode d. All of the above. Ge i ig Kg ei earTLWI certincation Train ay 28. \@ 29. \ 30. Wis Which of the following butt weld preparations is most likely to be considered for the welding of a 6mm thick plate? a. Double-V butt. 6, Asymmetrical double-V butt. oc Single-U butt. ©.) single-v butt Awelding inspectors main attributes include: a. Knowledge. b. Honesty and integrity, Cc. Good communicator. Cd.) allot the above, A code of practice for visual inspection should cover: Va Before, during and after welding. b Before welding activities only, After welding activities only 4. None of the above 5 Qu paper MSR-WE-1 issue I Date: 8/1/0283.3 § TWI cectitication & tr0 ee G 30 Welding Inspection, Steels — WIS 5 Multi - Choice Question Paper (MSR-WI-4) Name: AIS THUR BRUNE... Answer all questions 1. Degreasing components are essential for quality welding but when welded some agent may: _ a. Cause corrosion problems. b. Leave residues Give off toxic gases &&> All of the above. ~~ 2. Cellulose electrodes are often used for the deposition of a root pass on pipes welded in the field. This is because? a. Hydrogen control is required. b. The high deposition rate due ta the iron powder content. The hydrogen gas produced ir the flux increases the arc voltage. All of the above. 3. _ In the welding of austenitic stainless steels, the electrode and plate materials are often specified to be low carbon cantent. The reason for this: a To prevent the formation of crecks in the HAZ. €.) To prevent the formation of ch-amium carbides 1 c. To prevent cracking in the we! d. _ Minimise distortion4. With regards to a welding procedure. an essential variable may: a. Change the properties of the weld b. Influence the visual acceptance \4 c. Require re-approval of a weld procedure @) All of the above £~ 5. Which of the following NDT methods can only detect suriace breaking defects? & MPI AC YORE) Premancnt MAGNET 1S CAPABLE OF \ REVEALING SLIGHTLY SuB-SURFACE INDICNTIONG. b. DPI x c. UT gd. RT. 6. Which of the following defects would show up as light indications on a radiograph? @, Slag inclusions and copper inclusion ue G) Tungsten inclusions and excessive root penetration. i c. Cap undercut and root piping. d. Excessive cap height and incomplete root penetration 7. Which of the following electrodes is the most likely to contain the largest quantity of combustible organic compounds? 4 a Basic b. Acidic. ¢. Rutile. &) CetuoseTWI certitcation & trai WB 8. Lamellar tearing is best prevented by 2. The use of plate materials containing low levels of impurities b. The use of buttering runs. a Post weld stress relief. &) Both a and b. -~ e All of the above, 9. When considering radiography using X-ray, which of the following techniques is most likely to be used for a pipe to pipe weld (circumferential seam), 610mm diameter with no internal access? a. SWS! J ©.) Dwsl. ~ c. DWOI d. SWS|-panoramic. 10. A balanced welding technique for example back step welding is most often used for: a. Controlling lamellar tearing. o Increasing weld toughness. c. Reducing weld zone hardness © Reducing distortion. —~ 11. Basic coated electrodes have which of the following properties y be used to produce welds of high ~~ elds of low hydrezen content High mechanical properties m: deposition rates and to produce » Friable slag, high mechanical strength, and to proc.ce welds of a low 7 hydrogen content. xy Low hydrogen content welds. strength c Low carbon content welds, fi d stop/start prore~ies and high icole slag and high strengthTWI certitication Me 12. 13. On a radiograph, the most likely appzarance of lack of rot fusion on a single- V butt weld is: C@) A dark straight tine with a fight root a b. c. 4. A dark root with straight edges. A dark uneven line following the edge of the root None of the above lack of roo! fusion can nat be s2en on a radiograph What do you understand by the term minimum interpass temperature? Minimum post weld heat treatment applied to a weld. Minimum stress relief temperature. The lowest temperature to be used during preheat during welding ard between weld The lowest temperature allo passes. a Which of the following is applicable to a plate lamination They are best detected by radiography. They are mainly caused by hydrogen entrapment They originate in the parent material. ~~ They are caused when welding stresses act parallz! with the rolled direction of the parent plate. Which of the following NDT methods would be the least e“ective on an austenitic stainless steel butt weld. : a [/ UT. RT. caeTWI certication 1 We 16. The hardest part of a multipass welded joint, assuming 10 Post weld heat / 4 18. treatment has have taken place is 2 The HAZ of the cap. @) The HAZ of the root. ~~ ©. The root. d. The cap. 's it permissible to allow a single pess butt weld to,cool ¢own between weld passes? a It should be up to the welding inspector, b. No the weld must be kept he: at all times. c. It depends on the welder It depends on the specificatic requirements 4 A tee joint on a support bracket is to be welded both sides using a 5 mm leg length fillet weld, each weld is to be intermittent 50 mm in total length, the gap hich of the following is the correct between each weld is to be 25 mm. ‘symbol in accordance with ISO 255¢ 5 KX 25 (50) J 5x50 25) 5 25 (50) oN] 5x50 (25) ©. -LWI certitication & 1 UB 23. What does the 70 represent on an E70 10 AWS A5.1 classified electrode? 3. 70 N/mm? minimum UTS. 5. 70 joules minimum impact strength. 70,000 p.s.i. Minimum yield strength. a) 70,000 psi minimum UTS. “~ 24. Basic electrode provided in a standard packaging: * &) Should be baked as to manufactures recommendations prior to use we b. The baking conditions depend upon the welder. © Are recommended for use where porosity free welds are required vertical, and down hand ¢. Are only suitable for welding in the positions, 25. Cellulose electrodes have which of the following properties? a. Viscous slag, large volumes of shielding gas and UTS values above 90,000 psi. 5. Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 ml per 100g of weld metal ceposited Large volumes of shielding gas, 1ycrogen contents > 15 ml per 100g of ie weld metal deposited and shoulc be never baked, 3. High spatter contents, high deposition and large volumes of gas shield 26. , From the following electrode coding E50 4 B 160 20 H5. the compulsory part is: a E50 3 B 160 20 H5. s B 160 20 H6. ): £5048. _% None of the above. wile:28. /2 d. 29. TLWI certincation Training - 27. Which of the following is applicat.¢ to electrode efficiency? a. a b. c, gd. The mass of metal deposited as a percentage of the mass of core wire melted Iron powder electrodes ha: efficiencies above 100% Electrodes of high efficienc’es tend to produce welds of a smooth flat profile, Both a and b. Alll of the above A Fatigue cracks fracture surface ‘s: Rough randomly torn Smooth. -~ Step like appearance. Bright crystalline. £6014 electrode would most probably used for welding Low pressure pipework. ~~ High-pressure pipework Vertical down welding on stzrage tanks. Ina situation where low hyc-ogen welds are specified. 30. Which element in steel if present ir significant amounts miay lead to hot shortness? a d. c. Phosphorus. Manganese Silicon, ) sulphur,