⦁ You notice that a welder is using an unapproved WPS for production tack welding

carbon steel, what action would you take?

⦁ Have the tacks removed and MPI the weld preparation for cracking
⦁ Nothing as it is only tack welds and they will probably be removed anyway
⦁ Nothing as long as the WPS covered the material type, wall thickness and diameter
⦁ Give him the correct approved one and allow him to continue as long as the welding
consumables were the correct type

⦁ The welding procedure calls for a minimum of 500C preheat; you notice the welder is
using an oxy-acetylene cutting torch to preheat the butt weld joint, what course of
action would you take?
⦁ I would check the preheat with a temperature indicating crayon (tempilstick) to ensure
it is correct
⦁ I would stop him and insist he used an approved method which is nominated on the
WPS
⦁ It is acceptable to use this method of applying preheat so there is no problem
⦁ As long as he had a neutral flame it would be acceptable

⦁ Which is the most accurate method of ensuring that the correct preheat is applied?
⦁ Measure it with heat sensitive crayons (tempilsticks)
⦁ Using a calibrated digital thermometer
⦁ Using heat treatment equipment with thermocoulplesattached and a chart recorder
⦁ Temperature measuring paint

⦁ Which of the following would you not need to check in a welding consumable store?
⦁ The oven temperatures
⦁ Quarantined consumables
⦁ Calibration of the ovens
⦁ The humidity

⦁ In an all weld tensile test, the original specimen gauge length was 50mm, and after the
test the increased gauge length was 70mm, what is the elongation percentage?

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⦁ %A is 40
⦁ % A is 60
⦁ %A is 30
⦁ %A is 36

⦁ In a transverse tensile test, if the break was in the weld metal, the sample would be:
⦁ Acceptable if the UTS is equal to or greater than the specified UTS of the plate
⦁ Acceptable if the UTS is equal to or greater than the specified welding consumable
UTS but below the minimum UTS of the parent material
⦁ Rejected
⦁ Retested

⦁ The welders have increased the electrode stick out length of the SAW set, what would
be the effect on the weld?
⦁ No effect
⦁ The weld width would be narrower
⦁ Penetration will be increased
⦁ The deposition rate would be greater if wire feed rate is increased also

⦁ Why is the OCV voltage capped at a certain level?

⦁ Save electricity
⦁ Reduce the risk fatality
⦁ Prevent exploding of the consumables
⦁ Allow smooth transition into welding voltage range

⦁ During root welding, which of the following would be the main cause of lack of root
penetration?
⦁ The root gap is too large in accordance with WPS
⦁ Preheat was not used
⦁ The current is too low

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⦁ Root face is too small

⦁ Is it permissible to allow a welder to carry out a MMA (SMAW) welding procedure

test if he is not qualified?
⦁ No
⦁ Yes as long as the welding engineer is happy to allow it
⦁ Yes as long as he has a TIG (GTAW) qualification
⦁ Yes as long as no NDT is required on the finished weld

⦁ Which of the following electrode types would produce the lowest level of hydrogen?
⦁ Cellulose coated electrodes sealed in a tin immediately after manufacture
⦁ Basic coated electrodes when baked correctly immediately prior to use
⦁ Rutile coated electrodes when dried at 1500C prior to use
⦁ Heavy rutile coated electrodes when dried at 1800C for 2 hours prior to use

⦁ At what level is residual stress a problem when trying to minimize the risk of H2
cracking?
⦁ The stress levels have no influence on H2 cracking
⦁ The stress levels will need to be between 30 to 40% of the material yield stress
⦁ The stress levels will need to be greater than 50% of the material yield stress
⦁ The stress levels will need to be greater than 75% of the material UTS

⦁ At what level is the hardness value a problem when trying to minimize the risk of H2
cracking
⦁ 270 to 290HV
⦁ 300 to 350HV
⦁ 100 to 150HV
⦁ 160 to 200HV

⦁ Hydrogen cracking is considered a cold crack as it will not form until the weldment
cools to below:

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⦁ 5000C
⦁ 3000C
⦁ 3000F
⦁ 7300C

⦁ In a welding procedure transverse joint tensile test the following observations were
made. The specimen CSA was recorded as 40mm x 20mm and the maximum load
applied was recorded as 190kN. What is the UTS
⦁ 237.5 kN/mm2
⦁ 247.5 N/mm2
⦁ 24.5 N/mm2
⦁ 237.5 N/mm2

⦁ In a cross joint tensile test the following observations were made: Specimen width:
20mm, material thickness: 20mm, max load: 180KN, break position: parent plate.
What is the UTS?
⦁ 45KN/mm2
⦁ 450N/mm2
⦁ 39KN/mm2
⦁ 39N/mm2

⦁ Lamellar tearing is a problem in steels which is always associated with

⦁ Sensitization in the HAZ
⦁ Low through thickness ductility
⦁ Hydrogen levels above 15ml/100g of the weld metal
⦁ Rapid cooling from above the upper critical

⦁ Assuming the same materials and welding procedure were used, which of the

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 following would require the highest preheat?
⦁ Butt weld in 35mm plate
⦁ Cruciform joint in 25mm plate
⦁ Tee joint butt welded in 30mm plate
⦁ Tee joint fillet welded in 20mm plate

⦁ Lamellar tears in steel weldments may only be formed when:

⦁ Using deep penetration welding processes (high current density)
⦁ High levels of stresses act in the short transverse direction in the steel
⦁ Martensite has formed in the weld HAZ
⦁ Low melting point iron sulphide (FeS) has formed in the fusion zone

⦁ In welder qualification testing of 45mm thick plates, why are side bends used instead
of root and face bends?
⦁ They are easier to produce
⦁ The testing equipment cannot handle thick root/face bends
⦁ Root defects are not important for welder qualification
⦁ They give more accurate indications

⦁ When examining a completed bend test the angle of the bend was found to be 185 0.
The testing specification calls for the sample to have been formed through 180 0
⦁ They should be acceptable as the standard refers to minimum forming angle
⦁ The bends should be considered as failed
⦁ Non bends should be produced and bend to 180 0 then re-examined
⦁ They should be rejected as the angle is not close enough to be acceptable

⦁ When welding medium carbon steel plates over 120mm in thickness would the basic
electrodes require any pre-treatment before use?
⦁ None if they were in a vacuum pack
⦁ None if they were used in a factory
⦁ Heat if 5000C for 2 hours if used outside

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⦁ Baked at 1500C for 4 hours prior to use

⦁ What are the three metal transfer modes when using MIG/MAG (GMAW)?
⦁ Dip, drop and drag
⦁ Trailing, vertical, and leading
⦁ Pulse, dip and flood
⦁ Dip, spray and pulse

⦁ When SAW welding using twin wires with separate power supplied what should the
electrical characteristics be?
⦁ Both wire DC+ve
⦁ Both wires AC
⦁ The lead wire DC+ve polarity followed by the trailing wire using a AC polarity
⦁ Both wires DC-ve

⦁ What would the effect be if the polarity were changed from DC-ve to DC+ve when
MMA (SMAW) welding?
⦁ More penetration
⦁ None
⦁ Greater deposition rate
⦁ Less penetration

⦁ An80mm diameter pipe, 10mm wall thickness is to be radiographed using the double
wall single image technique. The source to be used is Iridium, which of the following
statements is true?
⦁ It should not be done as the thickness is below that recommended
⦁ It would better to use a cobalt 60 source in this instance
⦁ There no problem with the technique
⦁ preferred The method is the double wall, double image technique

⦁ While inspecting a weld on a 100mm thick high carbon steel plate with tolerance of +
5mm you noticed the weld is visual/acceptable, however the parent material has

6
 several arc strikes present adjacent the weld approximately 3mm deep, what course of
action would you take?
⦁ None I am only inspecting the weld
⦁ Recommend that the area be dressed smooth
⦁ Recommend that the area be dressed smooth followed by MPI
⦁ High carbon steel is not susceptible to cracking so I would weld over the arc strikes
then blend them

⦁ One of the advantages of ultrasonic inspection in relation to radiographic testing to:

⦁ Access is generally only required from one side (surface)of the component being
tested
⦁ The designated work area must be closed off by barriers, therefore safety is increased
⦁ Thin materials can be easily examined
⦁ A permanent image of the defect can be obtained

⦁ When reviewing a radiograph of a weld made by the MAG (GSMAW) process, you
notice a very bright white inclusion in the weld, which of the following best describes
this indication
⦁ Tungsten inclusion
⦁ Spatter on the cap
⦁ Copper inclusion
⦁ It is most likely to be a film mark

⦁ With which of the following NDE processes will BEST detect internal lack of side
wall fusion on a MAG (GMAW) weld
⦁ Visual
⦁ Dye penetrant
⦁ Ultrasonics
⦁ radiography

⦁ When MMA welding what will be the effect on the weld if the electrode was changed
from DC-ve to AC

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⦁ None
⦁ Higher deposition rates
⦁ There would be more penetration or a slight decrease in deposition rate
⦁ The arc would become unstable

⦁ When using DC-ve polarity, what is the typical OCV

⦁ 10-40V
⦁ 50-90V
⦁ 100-140V
⦁ 200-240V
⦁ A butt weld has been made by MMA in a 20mm thick impact tested steel plate. The
welding electrodes used was a basic types, 4mm diameter, the measured welding
parameters for one of the runs was not amps, 24 volts, using AC polarity, and an ROL
of 145mm/min. What would be the arc energy?
⦁ Insufficient information given to calculate the arc energy
⦁ 1.8kJ/mm
⦁ 2.9kJ/mm
⦁ 0.96kJ/mm

⦁ What would be the most likely SAW flux type for welding medium carbon steel
which requires impact testing:
⦁ Cellulosic
⦁ Rutile
⦁ Fused
⦁ Agglomerated

⦁ Which of the following defects is usually associated with the MAG (GMAW)
welding process when using Dip transfer
⦁ Centerline cracking
⦁ Lack of side wall fusion
⦁ Undercut
⦁ Tungsten inclusions

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⦁ The ease in which materials can be welded together is termed
⦁ Weldability
⦁ Jointability
⦁ Bonding
⦁ All of the above

⦁ Which welding process and mode is more susceptible to lack of sidewall fusion?
⦁ MAG Dip
⦁ SAW DC+
⦁ MAG Spray
⦁ TIG Pulsed

⦁ Standards on the same subject approved by different standardizing bodes, that

establish inter changeability of products, processes and services, or mutual
understanding of test results or information provided according to these standards are
called:
⦁ Codes of practice
⦁ Harmonized standards
⦁ Quality plan
⦁ Quality management systems

⦁ A main element involved in solidification cracking is:

⦁ Chrome
⦁ Molybednem
⦁ Sulphur
⦁ Silica

⦁ The purpose of a hot pass is to:

⦁ Improve fusion
⦁ Improve profile

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⦁ Remove hydrogen
⦁ Remove sulphur

⦁ For the structure termed martensite to form in a C-Mn steel it must first be heated to:
⦁ Just below its lower critical temperature and rapidly cooled
⦁ A maximum temperature of 5500C then rapidly cooled
⦁ Above its upper critical temperature and slowly furnace cooled
⦁ A full transformation to austenite then rapidly cooled

⦁ In replacing intermittent fillet welds, BS EN 22553 and AWS 2.4 differ in?
⦁ The way in which staggering is structure
⦁ The plot distance definition
⦁ Both the above
⦁ None of the above

⦁ Weld decay will cause which of the following problems

⦁ A reduced resistance to corrosion
⦁ A lower tensile strength
⦁ The toughness is reduced
⦁ The hardness will increase

⦁ The temperature at which chromium carbides are formed is ……………….

⦁ 350-5500C
⦁ 500-8500C
⦁ 500-10500C
⦁ 1050-15000C
45. The similarities between BS EN 22553 and AWS A2.4 in deciding welding symbols
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 are
A) Both have the same rule for depicting weld at round
B) Both have the same rule for depicting other side
C) Both have the same rule for depicting sequence of operations
D) Both have the same method for depicting welding process
46. cross sectional area dimensions are shown according to EN 22553
A) To the left of the symbol
B) To the right of the symbol
C) Under the reference line
D) In the tail at the end of the symbol
47. Why would visual inspection of the excess weld metal at the bottom of the a cross
country pipeline be important?
A) It is the most difficult area to weld
B) It is the difficult part of the pipe as it is near the ground
C) Welders always forget to weld the bottom
D) It is the most difficult area to radiograph
48. What information should be recorded has a minimum, on a completed production
weld?
Size and type of electrode used
B) Welding supervisor’s name
C) Welding identification, date and weld number
D) Welding Inspectors name
49) Why is it essential to clean the surrounding parent metal adjacent to the weld adjacent
to the weld metal made by MMA (SMAW) which is to be ultrasonically tested?
A) Sound waves will not travel through paint
B) Remove any rust
C) The spatter willimpede the contact of theprobe and the parent material surface
D) Spatter will reflect the backwall echo signal and give spurious indications
50. You find several unacceptable welds and reject them, the welding supervisor insists
they are acceptable, he sings them off and requests NDT, what action would you take?
A) Nothing as he is a welding supervisor and knows a great deal about welding
B) Raise the issue with the QC department supervisor
C) It is not my problem as he has signed them off so I will not be blamed
D) Look at the NDT results and if they look reasonable I would accept them.

51) Prior to production welding commencing you notice that the drawing has been
revised and now includes a pipe with a wall thickness of 30 mm, your WPS only
covers wall thickness of 28mm, what course of action would you follow?
A) Continuous with production welding as the differences is less than 10%
B) Apply for a concession to change the thickness to permit the welding on the 30 mm
wall thick pipe
C) Change the range on the WPS to 36mm and allow welding to commence
11
D) Allowing welding to commence then apply for a concession

52. voltage and amperage meters have been removed from MIG/MAG(GMAW)
equipment making calibration invalid, the equipment should be:
A) Quarantined
B) Only used for tack welds
C) Only used if validated
D) Monitored closely by the welding inspector for amperage and voltage.

53.Which of the following is a quantative test:

A)Bend test
B)Macro
C)Tensile test
D) Radiography

54. When examining a completed macro test the recorded hardness figures were 5HV
points over the maximum permitted what would your course of action be?
A) Apply for Consession
B) Reject the whole procedure
C)Request a retest
D) Accept it as only just over the permitted value

55. In welding procedure transverse joint tensile test the following observations were
made. The specimen CSA was recorded as 30mm x 20mm and the maximum load
applied was recorded as 200kN. What is UTS
A) 33KN/mm2
B) 333 N/mm2
C) 3333 N/mm2
D) 33 N/mm2
56. Which of the following defects are not associated with the SAW process?
A) Centreline cracking
B) Chevron cracking
C) Copper inclusions
D) Tungsten inclusions

57. Clustered porosity found internally in the body of an MMA weld is usually associated
with:
A) Poor inter-pass cleaning
B) The open circuit current being too high
C) Poor stop start technique or damp electrode coating
D) Low open circuit voltage

58. In which of the following modes of transfer is inductance usually a variable parameter
in solid wire MAG welding (135)
A) Dip transfer
B) Spray transfer
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C) Pulse transfer
D) Globular transfer
59. A disadvantage of the MAG (135) spray transfer condition is that it:
A) Cannot be used in the vertical position for steels
B) Cannot be used for aluminium alloys
C) Has a low heat input and is prone to lack of sidewall fusion
D) Is said to have lower deposition rate than dip transfer
60. An advantage of the MMA (111) welding process is that it:
A) Has higher current density than SAW (121) welding
B) Has a very large range of consumable for most welding applications
C) No core wire is lost during the process
D) Requires a lower skill level than other manual forms of welding

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