DESCRIBE (NOT USING SKETCH) THE MIG/CO/M AG WELDING PROCESS Welding power source is connected t0 the incoming main power supply. Higni voltage of supply received in the welding unit is converted to minimum voles and maximum. amps t0 suit the weldiag work, 7 » Power supply from welding unit is carricd to the work by means of welding cables. One welding cable is directly eonnacted to the work as a setur eable (earth cuble) Sean welding cable is accuinpunicsi by an eleetronic controlled p nser uu, shielding’ yas hose from gas cylinder and water eunling hoses fom w 1s out required for air cruled torches) ars connected 10 the motorized wite je (Irom power “cares wooling unit (water ve «nit From motorized wire drive unit through a flexible conduit the welding cuble (special type with wire spiral in.icle) is conneried to the welding torch accompanied by gas hose, water cooling hoses and welding ters electronic controlled (2 core) switeh wire In addition. ground earths ate provided to welding power source unit and (9 the work, vint of wa: | Proper deleet freeililler wire 2 Proper shielding gas selection and composition, S. Polarity selection 4. Perfect contiet af filler wire to the contact ube 5. Filler wire tip eutting Mode of Onerati An att is maintained beween she end of a bare wire eleetwode and the work. (hte wire is fed tw power souree L constant speed, selzeted 1 give requited current and the arc length is controlled by he operitor és no4 therefore concerned with controlling the, are length and he ean eongentrate on Cepositing the weld etal in the correct manner Henve the name is "seni, automatic" for manual operation, in which wire, gas and power are fed 0 9 iuind weld gan. vis & flexible conduit. ‘The process ean be operated at high currents (250 - S00A) when metal transler is in the form of a ‘spray’ onial positions Fey lip Hut axeepi for Aluminiwn, this technique is confined to weld in Mat and he welding in the vertical and overhead positions special low cunent techniques must be used, { ttunsfir ar pulsed are the are and weld poot are shielded by stream of sas. £ ical Defects 0 subbing out Lack of Fusion Incomplete pevetration Porosity Excess penett ion Under eu Stray Mush Excessive spatterWelding Inspection : Multiple Choice Questions Paper 1 (Rev. 2) Please return this paper unmarked Which mechanical rest can be used to aneasure the toughness of weld metal, HAZ and parent material? A macro Bo nick break C hardness -D. charpy impact ‘Which is the best destructive test for showing lack of side-wall fusion in a 25mm thick butt weld? A. Nick break “B-Side bend Charpy impact DA face bend test ‘The principal purpose of a welder qualification testis, A Towst the skill ofthe welder B. —_Toassess the weld ability of the enaterials C. Tedecice which NDT methods to use D. To give the welder practice before doing production weld A fabrication procedure calls forthe tocs of all welds to be “blended in” by grinding. The most likely reason for doing this is 10... A. Make the weld suitable for liquid (dye) penetrant inspection B. Improve the fatigue life C,—— Reduce residual stress 1D, Improve the general appearance ofthe welds, ion and profile are mainly influenced by. For full penetration single-sided but! joints, ot bead pent A. root face RB bevelangle “C. root gap D. include angle Undercu may need to be assessed according to A depth B. length C. sharpness / profile / blend -D.—allofthe above. ‘When visually inspecting the root bead uf a single-vee-bum weld it should be checked for. 2A. Igck of root penetration B-HAZ hardness C.— Tungsten inchision D. All of the sbave The strength ofa fillet weld is determined by. AL leg length B. weld profile © weld width vD. throat thickness TW Nu, andtonongh Fae oj poses 5 NAB AB URGAK {KiKeelteister is used foe the comm) ef penetsstion inte the base mater!” : DnMISA went + Yohage DB Welding Speed fron Powders in he coanng 5. Inthe welding of bun joint made ftom one nds, which of the following centrals the rood bead? 5 Reot Face B Bevel Angle © Reo Ge U Nene of C9 6a ype of power source characteristic is for manual welding? A Constant Vohage Bo Flat Characteristic © Drooping Characteristic D Motor Generator ~71 Which one of the following desructive ters would incicate the toughness of weld ‘mete pa met ~ A B Nick Break © Hardness D Charpy Vee Notch 1. Degreasing componens ae essential for quaity welding ut some agenss may A Cause Camrosion Problems B Give off Phosgene © ve Renidues {D Allofthe above 9. Whieh ofthe following chemical elenients has the greater eflect on the hardeability ofa steel plae? 2 Molybdenum Chromium Titanium coehave nef 2 MAGICO; welding, witch param: itr oF shor exteuing welowiy” A Ware stich-cur lengea © We ed eaeed P Inveisnee - In Misa welding, the slags produced ean b¢ varie€ 19 cut the weletay sesiiion; w slag wauld be requires for welding in the HV postion? Fuld None of the above D Semi fui ‘Tae weld metal deposit of menvsl | The Cote Wire 8 ‘ye Flux Coating Con powaers with the Mux coating nove to prevent the formation of pores constituent is nezded in 2 coating of n ele sing of rimming tieel? Iron Powders Caleta Fluoride A 2 © > Welds made with high heat inputs show 2 Calcium Carbonate suction in one of the Following properties? Pectin 3 Toughness Fatigue Sengen D Mechanical Serengsh In the welding of sustenitic pipework, ine bore if weually purged with Arie? A Prevent formation of porosity inthe weld Prevent huemethroweh sm the, r001 ram © erevent oxiaation of the root hes D Eliminate ihe formation of Hy In Xray work, the aualtty ofthe redtographie negative ts sssessed by the? A Density of he Fim B1gitn FypathrotigipieyeltWhat desamyctive 122; woud be rane 5 Nate bres! Sade bend est © Chagpy pace DB Aacro se sive penesration Change in weld mets! rampasiion Narrow weld wien 2 utd erin the hichlwood 36 cracking sv ah K.n 26. suinch wre Fle following fe aize! which has impre 2ienish’s heips ands smpeeve rent tnivteen™ 2 Corben Weleing 2 steel plate ofa ware preheanny 1? A Preven the formanen of suiph 8 nt hardening in the HAZ © —_-Prevent the formation of earbides D—Toimpraye mechanical progersies inthe wele . of the following procescer uses the "keyholing” ayster of f ietion welding. B_Diffucinn bonding Caer m welding D—Autogenous 11ts welding In inition welding, is the mesal atthe intariger in the? A Liguid state B Solid sae © Plestie ste D Eleetie site leg fe heat input High hea Welding procedures may require welds te be seposived a inputs would? A Have pect profile EB ave aveerorsin ove ©. Have high hardness in the #42 D. Have low elongation properi sure surtscé In 2 vensile test, 2 brittle material would be indicated f the 4 Shows s reduciien in size Bg Mat and featureiese SBreaks in he wels meted D ke in he parent mates!inva available D Stanchatt Bret 2 Beer nest © een quality ienied Deen vacuum meltes i would give rite to the formestion Which one of the following type of Jenouily welded wth an are proce A Fully willed need Bo Semi titled cine © immine steer D Fine grained steel In submeeped are welding, the use of excessively high valigge would resuls A Inguftnient Max “hing a seestive Puy metine Shae remove ait D Spener In the welding of austenitic stainless srezis, the sleetrede nd the plate with low carbon contents, The reason ‘er thi vs 16 prevent? A Cracking the HAZ The formation of chromium sarbins Cracking i the weld metal Submerged see Tuner can be supplied in sve forme, these 276% 5 Sintered ane a 2 Aguatee an fused © Crushed and sentomersies D fusew ands ‘The use of crllulosie elesnedes is ofte hiss because? 198! Pe poet A Hydrogen conn neese Bren powders in he electrode * Re Fipess Ben powders in de eecuode ohne Higher are voltage can be cbiaines ial A J Shorr are length can be 36Welding Inspection ; Multipte Choice Questions Paper 1 (Rey. 2) Please return this paper unmarked 9. The Furepean Standard for NDE of Fusion Welds by Viswal Examination is... AL EN288 vB. ENAQD. C EN287 D. -EN970 10, Visual inspection ofa fabricated jvem, for a high integrity application, should cover inspection activities. “A. Before, during and after welding B. Before welding only After welding only D. During welding and afier welding only 11. Incomplete root penetration in a single-vee butt weld may be caused by... AL Amexcessive root face B. Anexcessive root eap ©. The current setting being too low +D. — BothAandC 12. Incomplete root fusion in a single-vee butt weld may he caused by. vA. Linear misalignment B. The root gap being too large © Root faces being too smal! D. Allo the above 12, When visually inspecting the face of finished weld it should be assessed for A, Maximum excess weld metal height B. Toe blend C.Inter-nan blend YD. Allofthe above 14. A burnthrough may occur if A. The current is 190 low B, The root face is too large “C.—— The root gap is too large D. — Allefthe above 15. A Code of practice is A. Astandard for workmarship quality onty 7B, A set of rules for manufacturing 2 specific product CA specification far the finished product D.— Allof the shove 16. A solid inclusion in a weld may be YA Entrapped slag B —_Entrapped gas © Lack of inter-run fusion D. — Allof the above TY Necth, Méditesbrovth Frage 2 afpoges 5V. 18. 1g Inspection : Multiple Choice Questions Paper 1 (Rey. 2) Please return this paper unmarked Which of the following is planar imperfection? FA. Alack of sidewall fusion B.A shag inclusion Linear porosity D. Root concavity For fillet welds, itis normal practice in the UK. & USA to measure. YA. Throat thickness B, Leg lengths C_Penetration cepshs D. Boha&e Ina bens test, when the face of the specimen is in tension and roat is in compression, the testis calle. A, A root hend B.A side bend vo A face bend D. ‘A longitudinal bend ). Heavy porosity on the surface of some MMA welds made on a consiruetion site is most likely to be caused by Use ofthe wrong class of electraces The use of excessive current Moisture pick-up in the electrode coveri A bad batch of electrodes, pdpe Slag inclusions may be present in A Manual metal are welds B. Metal inert gas welds CSubmerged are welds D.— BothAand ‘The main cause of undercut is. VA. Excessive amps B Excessive volts C. Excessive ravel speed D. Alef the above Which group of welders is most likely 10 require continuous monitoring be a welding inspector’! A. Conetete shuttering welders bo B. Overland pipeline welders e C Tack welders =D, Maintenance welders Which of the following fillet welds is the st-onyest (assuming they are all made using the same material and welded using the same WPS)? A. Smm throat ofa mite fillet BT mmleg + 2mm excess weld metal C Mitre fillet with 10 mm leg YD. Concave filet with 11 want lew TH Nout, Atiddesoiongh Poges ofpagee §Welding Inspection : Multiple Choice Questions Paper 1 (Rev. 2) 27 Please return this paper unmarked AA typical included angle for MMA welding ofa full penetration pipe butt joint is. vA 3s 2B 708 c 9° D. Dependent on the pipe diameter A fillet weld has an actual throst thickness of &mm and a leg Teneth of Teen, what is the excess weld metal? A 2mm Bo 18mm © 3mm Do Lamm ‘The fusion boundary of a fillet weld is 4 ‘The boundary between the weld metal and HAZ ‘The boundary berneen individual weld nuns The depth of 1001 penewation ‘The boundary between the HAZ and parent material pops If Welding Inspector detects a type of imperfection not allowed by the Application Standard he must always. AL Request further NDE B Reject the weld C_ Prepare a concession request D. Only reject the weld if he considers it to be harnnful BS EN 870 allows the use of a magnifying elass for visual inspection but recomunends thatthe magnification is A x2 Bx 2t0xs Co xStox lo D. not greater than x 20 1. The majority of welder qualification tests are carried out using an unbacked joint, This is because.. itis quicker and cheaper if back-gouging is not required ifthe welding process is not TIG, back purging is not required all welder qualification tests are done oa small diameter pipe it requires more skill and increase the welders qualification range, Sere TW Soil, Shdiestrough Page 4 es $Multiple Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked 1, Deflection of the arc hy magnetic forces. tat can make welding difficult to control is cammonly known as Welding Inspection : ’ A ‘Are misalignment Q eHow Arc constriction 2. Which of the following electrodes is classified to BS EN 499? AU E8RR Bo E6013 Cc E70I8-G Do ESI3B 3. Which type of electrode is used for ‘siove-pipe” welding for overland pipelines construction? A. Rutile B. Cellulosic. ©. High recovery rutile D. — Allof the above C.& CMa steel a4 4. The three types of MMA electrodes used for wel Basic, cellnosic.and rutile Neutral, cellulosic and rutile Ras, celluosic and neutrel Rutile, low hydrogen and basie poe 5. A WPS may specify a maximum width fur individual weld beads (the ‘weave’ width) when welding C-Mn steels. If the width is exceed it may cause. Lack ofinter-run fusion: ‘A reduction in HAZ, tonighness Lack of sidewall fusion All of the above comm 6. You notice that MMA electrodes with the flix covering removed are being used as filler rods for TIG welding. This should not be allowed beeause, AQ This wasteful B. The rod diameter be too C. The weld metal composition may be strong D. The rod is 100 short, 7. For TIG welding, what benefit does s cu slope-out device have? A Inreduces Tungsten spatter B. Itreduces the risk of crarexcracking C. Mreduces the risk of are strikes 1D. treduces the imempazs temperature 8. Which type of power source characteristic is normally used for manual welding’? A. Constant veltage B. Flat characteristic C Constant cunrerte D. A motor generator Nom, Atieteongh Page 1 efpeges$ NANIM SAE (RH Aur S-LARZeetTIRg Inspection : Multiple Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked 9 Tn MMA welding penetration is principally controlled by AL Are voltage BL Welding speed ©. Ferro-silicon in the electrode coating D. cument, 10, Pipe bores of some materisis must be purse with argon before end during TIG welding in order to, A. Prevent linear porosity Bo Prevent burn-throueh Prevent oxidation ofthe rootbead D. —_Fliminste moisture pick-up in the root bead 11. ‘The chemieal composition of the weld metal deposited by a C-Mun steel MMA electrode is usvally controlled by A. The core mire composition B. Additions in the flux casting C. Iron poweer in the fx coating D. Dilution fromm the base material 12, Silicon is added to steel and the covering of MMA electrodes in order to give AL Deonidatian TR. Improved strength Improved toughness D. More resistance to hydrugen cracking A fusible insert for TIG welding helps to, Reduce porosity Give controlled 1901 pene ration Avoids the need for a back purge Allorthe above pps» 14, According to AWS 2.4 a weld syinbol for the ‘other’ side is placed. Above the dashed line Below the dashed line Above the solid line. Below the solid line pap 15, When low hydrogen MMA electrodes are specified for what type of covering will they have? pop> y 16. Alndrogen controlled MMA electrode can alvtay' be reco A. EN code letter (or AWS code number) B. Electrode le ©. Trade Name D. Colour af the covers PUD Monat, Middlesea Page 2 ofpageesWelding Inspection : Multiple Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked 17, According to BS EN 22553 which of the following symbols requires weld toes to be smoothly blended on the ‘ot side"? A B c D. 18, Which of the following units is used to express Heat Input? A Joules Bo N/mm mnt D. kvm 19 Which one of the following elements is added to stee! to ive resisisnee to creep at elevated service temperatures? A Nickel Bo Manganese C Molybdenum D. Aluminum 20. Nick break and fillet fracture tests are used for. A. Assessing weld quality: B. Assessing weld metal ductility CAssessing weld metal toughness D. — Allofthe above 21. Which of the following steels is non-magnetic? 18% Cr, 84 Nis 225Cr Me Cr, IMo % Ni A B c De Weld spatier during MMA welding is most likely to be caused by A. Excessive current B. —_Incomect baking and siorsge of elecnodes Abad batch of electrodes D. ——Allof the above PHY Nosh, Midetotwigh vere pages 5Welding Inspection : Multiple Choice Questions Paper 2 (Rev. 2) 27, 28 29, UE Novi, Aas lease return this paper unmarked - A qualified Welding Procedure Specification is used to Give instruction to the welder Give information to the welding inspector Give confidence that welds will lave the specified properties Allofthe above pney ded by some codes as unacceptable because... ‘Anare strike (stray flash) on steel component is rev A. [twill cause copper contamination B. Inmay cause hard spots c It may give cracks D. OfbathB &C In a transverse tensile test, brittleness would be indicated if. ‘A, There is a reduction in e1oss-section at the position of fracnure B The fracture surface is fat ard featureless but has a rough surface C—Fracwire occurred in the weld metal D. The fracture face shows beach marks The surface of a fatigue erack will A. Be rough and torn B. Have sharp chevron ma & Be sewoth 1D. Mave sheat lips What does the number I4I refer 1 om this drawing symbol? AL The WPS number B The welding pracess CA filler material ra D. The acceptance standard ‘The polarity used for TG welding of all miaterints except aluminum and magnesium is AL DC negative B. DC positive co ac D. Amy polarity ‘A typival temperature range for baking low hycrogen electredes is, 150 r0 200% 200 t0 250°C 300 10 350°C 00 16 480°C pose . Hf welding travel speed is doubled but the current and voltage remain the same, the heat input will AL be reduced by £08 B. be increased by a factor of two C. be about the same D. be reduce by approximately 25%TED, Alec WELDING INSPECTION, STEEL — WIS 5 MULTIPLE CHOICE QUESTION PAPER (MCQ.001) None eG reeort4 Answer all Questions When“ control” is specified for a manual metal are welding project he elsetrade would normal be A. Cellulosic B. Iron Oxide Cel Do Basic controlled flux covered electrode from i You would certainly recognize a hydrog A. Color Ro Length C. Trade Name D.AWS/BS639 cade Lester When manual metal are welding is bei likely to require continuous monitor carried out on am open construction site, which group of welders are mos A. Concrete shuttering welding teams Pipe welding team. Plater welders D. Plant Maintenance welders You notice manus! metal are electrodes, stripped of flux are being used as filler wire for TIG welding, You would object because A. Thisteo expensive B. The wire would be too thick ©. ‘The weld metal composition may be wrong D. The wire is too short When open site working, serious porosity ini metal are welds is byought to your attention, What would you investigate? Electrode type Power Plant type Electrode storage Day temperature por ‘The steel composition in a structural contiact is changed fiom 0.1% carbon, 9.6% manganese to 0.2% carbon. 1.24 manganese, Might this influence the incidence of Porosity Cracking in the weld area Undereut for fillet welds Lack of root fusion defects coeJ 10. PHP tk, Aid Which of the following alloy in non-magnetic? 4.0% Chyomium molybdenum 12.0% Chromuans Austenitic Stainless Steel 9.0% Nickel Sieel pee When TIG welding Aus called for. This i to. te slainless sicel pipe, argon was bak Prevent oxidation Prevent underbead cracking Prevent porosity Control the penetration bead shape poe Pre-heating a Carbon stee] manual metal are welding is carried out to minimize the tisk of, A. Scattered porosity B Warm hole porosity C. Parent metal cracking D. Lack of penetration In UK practice, BS499 Part 2 specifies that the drawing dimension quoted fora fillet weld is the: 4 Leg length B. Actual throat thickness ¢ Weld width Tor open site manual metal welding the following equipmienl is available, which would you choose for safe working? AL Single operator transformer B. Multi operator transformers C ACIDE composite power unit D. Diesel engine driven motor generator A welder qualification testis to verify A The skill ofthe welder B. The quality of the materials C. The non-destructive test procedure D. The manufacturing methods AA Tabricatin Procedure calls for fillet welds to be “blended in” by grinding. This isto influence. A. WAZ Cracking B Fatigue life Residual stress D. Yield strength Blend fst specimens have been taken fora 25mm thick carbon steel futt weld, Which woukl show lack of inner. san fusion, A Side bend Be Root bend © Face bend D. Guided bend Page Det gdJ, 15: Lamellar tearing has occurred ina ste! fabrication, BEFORE weeing eld it have bees Found by pore VY 16. You are ty oversee the are welds goes beh Mek Metrnagh ee wel ound be OCF X-ray examination a 7 4 Dye penetant Ulreronic inepestion Ie would ot have Been found by any mspection method of seme muchined ft ays and found they are cadmium plate Would yout Permit itt proceed Permit it w proceed with fume exitaction Stop the operation at once Advise the welder to drink milk and proceed! Pate SalpawesSUBMERGED ARC WELDING PROCESS ciRCUIT: Welding power source is connected to the incoming main power supply. High voltage of supply recetved in the welding unit converted (o minimum volts and maximum amps to suit the welding work, Power supply from welding unit is carried to the work: by means of welding cables One welding cable is divectly connected to the work as « retumn cable (earth cable), Second cable is accompanied by electronic controlled power cable from power source unit are connected to weldine head (control panel. wire drive unit. wire Sooo!), welding head, flux hopper uri are fived on dispenser traversing unit which will operate from direct power s Sn addition, ground earths are provided from welding unit and from work. 1. Proper tefect tree tiller wire (Wire spool). Flux and filler composition should be correct. 3. Tracki 4. Flux shoud be tree from dust and to be beked. filler metal deposition Mode of Operation: An dre 1s maintained between the end of a bare wire elecwod2 and the work As the melted, 113 fed in to the are by a set of rolls, eriven by a govemed motor lectrode is Wire feed speed is automatically controlled to equal the rate at which the electrode is melted, thus are length is constant. (or is similar to MIG/MAG constant voltage.) The are operates under a layer of graimilan sux (sen scomeiged are) Sore of the flux melts to provide a protective blanket over the Weid poui, she remanaer uf the flax is unaffected and can be recover-sd and re-used provided it is dry and not contaminated. A semi smtomatic version: is available in which the operator has control of a welding gun which carries a small qu ity of fix wn 8 hopper. Typical Defeots Misracking Incomplete penetration Porosity Excessive penetration Cracking Weld profile defects ‘Slag inctusion Under cut Lack of fusion Other Points auromared, teas Fiat are process (constant) vonge. High deposition rateOther Points The process 1s a lat arc (constant voltage}, Inert or active gas shieiding gas process. It is & sem automatic / fully automatic welding process Operating Parameters Current rage 60-500, Deposition rate 1 +10 Kgfhr (2-201b/s) Range of thickness Dip transfer & pulsed exe 0.5mm (0.020 inch) upwards, Spray transfer 6mm (1/4 inch) upwards Type of joints All welding joints, including spot welds. Wel-fing position Dip transfer & pulsed are - all position Spray tansfer - flat (T-joints only HLV.) and with Aluminum spray transfer can be used in al! positions Access ‘ Fair Postabitity . Fair ivantages:- Fast welding process. Thun to thick materials can be welded, Disady tages: Root & side ws! lock of fusion, easily can't be seen on radiograph Shielding gas is sensitive to wind and drafts. Ad) 1. Deposition rate is high. Costs are low because there is less electrode waste, no slog removal and welder down-time due to changing electrode is less compared 10 SMAW or GTAW. It is very versatile (all position process for Carbon, Low alloy and Stainless steels) Disadvanta: 1. Cost of machinery. shielding gas and maintenence is high, 2 Accessibility to the welding is restrictive because of the size af 3. Shielding ges is sensitive w wind and drafts, 4. The length of the welding lead (cable) is restrictive 5. The eq not portable as SMAW. omentLimited welding position (FLAT & HORIZONTAL) Run in & run off plates may be required Wire feed speed is adjusted automatically to equalize the rate of melting Jength constant, (Control patie!) filler wire to keep the are Advani Hi igh utilization of electrode wire Weld pudate is submz.ged, eliminating the need for provect ve clothing / Welding helmet, Little or no fume: sadvantages Nigh heat inpu that could be detrimental te some base metals Weld puddie not visible ‘Type of Mux used for SAW 1. Fused |2, Aggtomerated Tr Mux also called neutral type flux, mo alloying | Agglomerst=4 flux contains allovine elements elements, deoxidizing or tynizing agents are | deoxidizing agent and ionizing cent ete added to the Mux tis a basic type flus This a ordinary rutile ny-eflux Its Black » > Blakish gray ), thas 9 flakey shape, Kas light grey in color own in color or Very atk (11 nasa spherical shape It absorbs moisture, therefore pre-heating is required lass like appearance Motsiare resist, therefore no prebeating 35 1 ives bast mechanical reper End of the shift on daily basis to be removed from Wis used for General purpose similar so rite | BR thoppce to prevemt moisture absorption, clecuodesWelding Inspection : ‘Multiple Choice Questions Paper 2 (Rev. 2) a “2 3 va v5. v 6 vi uv 8 Please return this paper unmarked Which type of submerge are welding flux is suscepiible 10 moisture pick-up? AL Neutral B. Agglomerated Cc Fused D. They are al about the same A large grain size, in the HAZ of a C-Ma steel weld joint may have.. AL Lowduciiliy B. Low toughness © High toughness D, High tensile strength ASTRA test is used to measure. A. The tensile strength of the welded joint B. The level of residual stress in butt joints C. The fracture toughness of the HAZ DB, The through thickness ductility of a steel plate (the “Z” direction) ‘The risk of hydrogen cracking is higher when MMA welding of. CM steels Austenitic stainless steels Low alloy stecls for elevated temp. service ‘Low carbon steels for eryogenic service perp ‘The property of a material that has the greatest influence on welding distortion is the... ere Yield strength Co-efficient of thermal expansion Elastic modulus Corcficient of electrical conductivity pos> ‘Which ofthe following is a suitable shielding gas for FCAW of stainless steels? A. 100% Argon B. 70% Argon + 30% He Argon + 5% Hydrogen B. Argon + 20% CO; ‘The presence of iron sulphides in a weld bead may cause A. Solidification cracking B. Hydrogen eracking Lamellar tearing D. Weld decay ‘A macto section is particularly good for showing the HAZ microstructure overlap the weld metal microstructure all of the above pope THD North Muidlesiroush age | ofpages $‘Welding Inspection : ‘Multiple Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked V9. Which ofthe following procedures would be expected to produce the Icast distortion in I Smm straight burt weld? TIG weld single sided, multi-pass MMA weld single sided, multi pass MMA weld double sided, multi-pass SAM weld 1 pass per side pomp 7 10. A suitable gat / ga mixture for GMAW of alumi is. A 100% CO, B. 100% Argon C—_ 80% Argon + 20% CO; D. 98% Argon + 2% 0; wai ‘Which of the following is associated with SAW more often than it is with MMA welds is? A. Hydrogen cracking in the HAZ B, Solidification cracking in the weld metal ©. Recheat cracking during PWHT D. Lamellar tearing 12, EN 180 5817 (LEVEL C) specifies thatthe limit for the diameter (D) of e single pore in a weld is..-D<0.4s, but ‘max dima where s=material thickness For which of te following sition isthe pore accentable? A. 520mm, measured pore diameter = 5,0 mm B) 515mm measured pore diameter = 4.3 mm © S10 mm measured pore diameter =3.0 mm D. — s=10 mm, measured pore diameter = 35 mm 13. To measre re voltage accurately its recomended tht he voltmeter shold be comected ‘A. across the are and as near as practical tothe ar B, across the power source terminals prior to are initiation C_ across the power source terminals during the welding operation D. —_allofihe shove are suitable v/ 14. Lamellar tearing has occurred in a steel fabrication. What technique could have been used to find it before the weld ‘was mde? AL Xray examination B. Liquid penetran: examination Ultrasonic examination D. __Itcould not have becn found by any inspection method 18. Pre-hting sow alloy sel prior to welding done to minimize the isk of 6 A porosity B. excessive distortion CC HaZeracking D. Lack of fusion ‘Typical temperatures used for normalizing a C-Mn steel plate are AL 60010 650% B. 10000 100°C C. 700 t0 800°C < D. 880 10.920°C TW Korth, Maesbroueh Pare? ofpoges $Welding Inspection : Multiple Choice Questions Paper 2 (Rev. 2) “ny. 19. a. v2. 24, Please return this paper unmarked For GMAW the burn-off rate of the wire is directly related to A. thestick-out length B. wire feed speed © theare volioge D. the mavel speed For MMA welding of 60 ram wall nozzle ta 100 mmm wall vessel shell pre-hea temperature should be checked Before welding starts/r-starts (On the shell and the nozzle ‘At points at least 75mm from the joint edge Allofthe above pop> ‘A-crack running slong the centerline of @ weld bead could be caused by. Use of damp fax. Lack of preheat Are voltage being too high ‘Weld bead being too deep and very narrow pomp 'norder to improve resistance 1 service faire eaused by cyclic loading, it it good practice to, ‘A. Use low heat input welding B. Use steel with a low CEV C. Ensure there are no features that give high stress concentration D. —Alllofthe above ‘The use of low carbon austenitic stainless steels and established stainless steels will minimize the risk of AL HAZ cracking B. Weld decay C Weld metal cracking D. distortion Which type of SAW flux is susceptible to breaking down into fine particles during cireulation? AL Bused B. Neunal Cc. Alloyed D. ——Agglomerated The maximurn hardness in the HAZ of a stecl will increase if the . A. Heat input is increased B. CEVis increased ©. Joint thickness is decreased D. —Alllofthe above BS EN ISO 5817 (Level R) specifies the limit for excess Weld Metal (h) on a butt weld as:-h< I mm +0.1 », but max 5 mm, b-weld width, qh which of the following situations is the measured Excess Weki Metal acceptable? A, b 10 measured exeess weld metal = 2.5 min B. b= 20 measured excess weld metal ~ 3.5 mm C. b= 35 measured excess weld metal = 4.5 mm D. b= 4S measured excess weld metal = 5.5 mm VE North Middesbreush Pepe ef pogce §Welding Inspection : 2s, 26, 28. 29 30. TWINorth, Middesbough Multiple Choice Questions Paper 2 (Rev. 2) Please return this paper unmarked A carbon manganese ste! is being welded by MMA and the electrode man-out-lengths that have been used are muct shorter than specified by the WPS. This deviation may give... A B c. D. An increased risk of hydrogen cracking An increase risk of solidification cracking Lower values of HAZ toughness Higher values of HAZ hardness The first procedure that is prepared for a Weld Procedure Qualification test weld is a... A. B. c D. pWPS Wes WPQR WPAR _ansfer of material identification by hard stamping is sometimes not allowed for high integrity applications because ppp i is 00 slow it cam be safety hazard Itmay be damaging to the material All of the above ‘When welding thin plate, distortion ean be minimized by A B. c D. using back-step welding minimizing weld volume using bridge tacks all of the above ‘Which of the following would be considered to be high Heat Input welding? cap> 550 Yimm 55 Jimm, 5.5 Vm 5.0 ki/mam Tnitiation ofa TIG are by using a High Frequency a High Frequency epark may not be allowed because A. B. c D. Ttoften causes tungsten inclusions Itcan damage electronic equipment It is an clectrical safety hazard Troften causes stop/start porosity Pege def pagesSUBMERGED ARC WELDING PROCESS CIRCUIT: - Welding power source is connected to the ineoming main power supply. 2 High voltage of supply received in the welding unit converted to minimum volts and maxi to suit the welding work, Power supply from welding unit is carried to the work by means of welding cables. One welding cable is divectly connected to the work as a retum cable (earth cable), Second cable is accompanied by electronic controlled power cable from power source ut connected to weldine head (control pane}. wire drive unit. wire sonol). welding head, flux hoppe are fixed on dispenser traversing unit which will operate from direct power =: ue =} In addition, ground earths are provided from welding unit and from work. Point of weldin 1, Propa ‘fect tree tiller wire (Wire spool). 2, Flux and filler composition should be correct. 3. Tracking of filer metal deposition 4, Flux shou's be tree from dust and ro be baked Motte of Operation: An dre is maintained between the end of a bare wire clectrode and the work. As the electrode is melted. itis fed in to the are by a set of rolls, criven by a governed motor. Wire feed speed is automatically controlled to equal the rate at which the electrode is melted, thus are Jenath is constant. (or is similar to MIGMMAG constant voltage.) The arc operates under a layer of granular siux (iienee szomeiged are) Sov of the flux melts to provide a protective blanket over the weid povi, sie remancner uf the flay is unaffected and can be recovered and re-used provided it is dry and not eontaminated, A Semi suitomatic version is available in which the operator has control of a welding gun which caries a small quetity of ux in a hop; Typical Defects Mis-tracking or Incomplete penetration Porosity Excessive penetration Cracking Weld profile def Slag inelusion Under cus Lack of fusion ts automated, Fiut are process (constant) voltage High deposition rateWELDING INSPECTION, STEEL - WIS 5 MULTIPLE CHOICE QUESTION PAPER (MCQ.(01) None Ale Ct 203s 4 Answer all Questions a control” is specified for a rmanual metal are welling project the eleetrade would normal be A. Cellulosic B. Tron Oxide c. Acid D. Basie 2 You would certainly recognize a hydrogen controlled flux covered electrode from its A Color B. Length C. Trade Name D. —AWS/ BS639 code Leer \/ 3 When manual metal are welding is being eartied out on an open construction site, which group of welders are mast likely to require continuous monitoring? A, Concrete shuttering welding teams B. Pipe welding team, C. Plater welders D. Plant Maintenance welders V/- 4. You notice manual metal ar electrodes, sipped of ux are being used as filler wire for TIG welding. You would object because: A. Itis too expensive B. The wire would be teo thick C. The weld metal composition may be wiong D. The wire is too short V/ 5. When open site working, serious porosity in metal are welds is brought to your attention What would you investigate? A. Electrode type B. Power Plant type C— Bleenode storage D. Day temperamre V8 The steel composition na structural contract is changed fiom 0.15% carbon, 0.6% manganese 10 612% carbon 1.2% manganese, Might this influence the incidence of Porosity Cracking im the welt area Undereut for fillet wekis Lack of roo! fusion defects por PY Non, Misch Page Fofpages 4vB v9. fw TE Nin Maesteg Which of the following alloy in non-maynetic? 4.0% Chromium nvolydonum Austenitic Siainless Stee! 9.0% Nickel Stee! sealed for. This & 10. Austenitic stainless steel pipe, argon gas ba Prevent oxidation Prevent undeitead cracking Prevent porosity Coniol the penetration bead shape v. 2, c D. Pre-heating a Carbon steel manual metal arc welding is carried out to minimize the risk of. A. Scattered porosity B.— Warmhole porosity Parent metal cracking, D, Lack of penetration In UK practice, BS499 Part 2 specifies that the drawing dimension quoted fora fillet welt isthe A Leglengeh B Actual throat thickness Cc Weld width For open site manual metal welding the following equipnvent is available, which would you choose for safe working? A. Single operator wansformer B. Multi operator transformers © —-ACADC composite power unit D. Diesel engine driven motor wenerator A welder qualification testis to verify... A. The shill ofthe welder B. The quality ofthe maceriats C. The non-destructive test procedure D. The manufacturing methocs ing procedure calls for fillet welds to be “blended in” by grinding, This isto influence HAZ. Cracking Fatigue life Residual stress Yield strength poe Blend test specimens have been taken fiom 4 25mm thick esrbon seel butt weld. Which would show lack of inner ran fusion. A. Side bend B Root bend e D.J 15 Lames tearing has occured in a steel fabuication BEFORE welding could it have been fou by 1 wells Geant by ety, X-ray examination abe fe Bete Geer Dye penevrant Uiasonic inspection would nor have been foun hy any inspection method pow> 16 You ate to oversee the are welding of come machined fininas and found they are eadmiuns plate. Would you Permit it to proceed Permit it wo proceed with fime exwaction Stop the operation at once Advise the welder fe drink null: and proceed) pops Tt Suh, Middlesea eh Page aj posis 4WELDING ciRcurT: - Welding power source is connected to the incoming main power supply. High voltage of supply received in the welding unit converted to minimum velts and maximum amps to suit the welding work. Power supply from welding unit is carried to the work by means of welding cables. ‘One welding cable is direcily connected to the work as return cable (earth cable), Second cable is accompanied by cicctronic controlled power cable from power source unit arz connected to welding heed (control panel. wire drive unit. wire soool). welding head, flux hopper unit are fixed on dispenser traversing unit whieh will operate from direct power supply in adcition, ground earths are provided from welding unit and from work. Point of welding: feo tice tiller wire (Wire spool) 1 Proper 2. Flux and filler composition should be correct, 3. Tracking of filler metal deposition 4. Fluy show'd be tree from dust and to be baked. ‘An lire is maintained between the end of « bare wire electrode and the work. As the electrode is melted. itis fed in to the are by a set of rolls, driven by a governed motor. Wire feed speed is automatically controlled to equal the rate at which the electrode is melted, thus are length is constant. (or is similar to MIG/MAG constan: voltage.) The are operates under a laver of stale thus tenes acemesged arc) Son's of the flux melts to provide a protective blanket over the weid povi, she e-manaer uf the Mux is unaffected and can be recoverd and re-used provided itis dry and not conteminatcc. A semi shtomatic version is available in which the operator has control of a welding gun which carries a small qutity of fats sn a hopper. y ee Mis-tracking Incomplete penetration Porosity Excessive penetration Crackit Weld profile defects Slag inclusion Under cut Lack of fusion Other Points Easily automated Fia are process (constant) voltage. High deposition rateOther Points ‘The process 1s a flat are (constant voltage). Inert or active gas shieiding eas process, It isa semi arxcomatic / fully automatic welding process. Operating Parameters Current rage 60 - 5004, Deposition rate 0 Kahr (2-201b/hr) Range of thickness Dip transfer & pulser ere 0.5mm (0.020 inch) upwards. Spray transfer Gmm (1/4 inch) upwards. ‘Type of joints All welding joints, including spot welds. Wel Sing position Dip transfer & pulsed are - all position. Spray transfer - flat (T-joints only H.V.) and with Aluminum spray transfer can be used in all positions Access : Fair Portability Fair Acivantages: Fast welding process. Thin to thick materials can be welded Disadvantages: Root & side w-! lack of fusion, easily can’t be scen on radiograph Shielding gas is sensitive to wind and drafts Advantages: Deposi Costs are low because there is less electrode waste, no slag removal and welder down-time die to chanwing electrode is less compared to SMAW or GTAW. rate is high 3. This very versatile (all position process fo: Carbon, Low alloy and Stainless steels) Disadvantages: 1. Cost of machinery. shielding gas and mainenonce is high Accessibility to the welding is restrictive because of the size af Shielding gas is sensitive 'u wind and drofis, The length of the welding lead (cable) is restrictive The equ: ment is not portable 2s SMAW.Limited welding position (FLAT & HORIZONTAL) Run in & run off plates may be requited Wire feed speed is adjusted automatically to equalize the rate of melting of filler wire to keep the ars Tength constant, (Control nanel) Advantages High utilization of electrode wire Weld pudste is subr:=rged, eliminating the néed for procective clothire / Welding helmet Little or no fumes Disadvantages High heat inpu: chat could be detrimental Some hese rretals. Weld puddle not visible. ‘Type of flux used for SAW 1. Fused | 2. Aggtamerated ing alloving elements Th ux also called neutral type flux, no alloying | Agglomeratzd Mux x elements, ceoxidizing or iztizing agents arc | deoxidizing agent and ionizing seen’ ete adged to the Hux. Iisa basic type flux Iisa orenary rutile eyeflux iets Vahey es ee It is Black » own in color or Very daric ( Blakish gray). Ithas 2 flakey shape, Glass like appearance. Ithas a spherical shape, It absorbs moisture, therefore pre-heating | required Moisuwe resissant, therefore no preheating 1S gives pest mechanical properties required. 7 Tt is used for General purpose similar to rutile slectrodes End of the shift on daily basis to be removed from the hopper to prevent moisture absorptionWelding Inspection : Multiple Choice Questions 41. ws Please return this paper unmarked ‘Which type of submerge arc welding flux is susceptible to moisture pick-up? A. Neutal B.—Agglomerated C. Fused D. They are all about the same A large grain size, in the HAZ of a C-Min steel weld joint may have. A. Low ductility B—_Low toughness C. High toughness D. High tensile strength ASTRA test is used to measure... A. The tensile strength of the welded joint B. The level of residual stress in butt joints. C. The fracture toughness of the HAZ B. The through thickness ductility ofa steel plate (the “2” direction) ‘The risk of hydrogen cracking is higher when MMA welding of... Mn steels Austenitic stainless steels Low alloy steels for elevated temp. service Low carbon steels for exyogenic service yoe> ‘The property of a material that has the greatest influence on welding distortion is the A. Yield strength B. —_Co-efficient of thermal expansion Elastic modulus D. Coefficient of electrical conductivity Which of the following is a suitable shielding gas for FCAW of stainless steels? A. 100% Argon B. 70% Argon + 30% He Argon + 5% Hydrogen DB. Argon + 20% CO; The presence of iron sulphides in a weld bead may cause. A Solidification cracking B Hydrogen cracking C. Lamellar waring D. Weld decay A maczo section is portieularly good for showing, the HAZ microstructure B. overlap C. the weld metal microstructure D. —allof the above THEY Nerth, Midesbrough 2 Rev. 2)/e~ SPaperPrseg 1°"Welding Inspection : Multiple Choice Questions Paper 2 (Rey. 2) v 9, 10. VY i Please return this paper unmarked Which of the following procedures would be expected to produce the least distortion in 15mm straight butt weld? TIG weld single sided, moulti-pass MMA weld single sided, multipass MMA weld double sided, multi-pass SAMweld 1 pass per side pap> A suitable gas / gas mixture for GMAW of aluminum is, A. 100% CO, BL 100% Argon © 80% Argon + 208% CO, D. 98% Argon + 2% 0; |. Which of the following is associated with SAW more often than itis with MMA welds is? Hydrogen cracking in the HAZ Solidification cracking in the weld metal Re-heat cracking during PWIHIT Lamellar tearing pop> EN 150 5817 (LEVEL C) specifies thet the limit forthe diameter (D) ofa single pore in a weld is....DE0.36, but ‘max 4mm where s~material thickness For which ofthe following situation is the pore accsptable? A. s=20 mm, measured pore diameter = 5.0 mm B.s=15 mm measured pore diameter = 4.5 mm c. D. s=10 mm, measured pore diameter ~ 3.0. mm ‘s=10 mm, measured pore diameter = 3.5 mm ‘To measure are voltage accurately itis recommended that the volimucter should be connected ‘A. across the are and as near as practical to the are BR, —_ across the power source terminals prior to arc initiation across the power source terminals during the welding operation D. —_allof the above are suitable Lamellar tearing has occurred in 2 steel fabrication. What technique could have been used to find it before the weld was made? A, Xeray exemination B. Liquid penetrant examimation C.— Ultrasonic examination 1D. —_Itecould not have been found by any inspection method Pre-heating 2 low alloy steel prior to welding is done to minimize the risk of. ‘ AL porosity B. excessive distortion CHAZ crac D, Lack of fusion Typical temperatures used for normalizing a C-Mn steel plate are A. 600 t0 650°C B 1000 ta 1100°C C700 10 800°C D. 88010 920°C THI North, Middlesbrough Page of pes §Welding Inspection : Multiple Choice Questions Paper 2 (Rev. 2) 17. 19. 20. “4u. 22. UB THE Hot, Mistestrougt Page dof Please return this paper unmarked For GMAW the burn-offrate of the wire is directly related to. the stick-out length wire feed speed the arc voltage the travel speed pnp For MMA welding ofa 60: mm wall nozzle to a 100 mm wall vessel shell, pre-heat temperature should be checked Before welding star/re-sterts (On the shell and the nozzle At points at least 75mm from the joint edge Al of the above gom> A crack running along the centerline of a weld bead could be caused by... AL Use ofdamp flux B. Lack ofpreheat Cre voltage being too high D. Weld bead being too deep and very narrow In order to improve resistance to service failure caused by cyclic loading, itis good practice to A. Use low heat input welding B, Use steel with a low CEV C. Ensure there are no features that give high stress concentration D. Alef the above ‘The use of low carbon austenitic stainless steels and established stainless steels will minimize the risk of. A. HAZ cracking B. Weld decay C.— Weld metal cracking D. distortion Which type of SAW flux is susceptible to breaking down into fine particles during circulation? A. Fused B. Neutral Cc Alloyed D. —Agelomerated ‘The maximum hardness in the HAZ of a steel will increase ifthe Heat input is increased CEV is increased Joint thickness is decreased All ofthe above soep BS EN ISO 5817 (Level B) specifics the limit for excess Weld Metal (h) on a butt weld as: -h< | mm_+0.1 b, but max 5 mm, b=weld wide In which of the following situations is the measured Excess Weld Metal acceptable? A. b= 1D measured excess weld metal = 2.5 mm B._b= 20 measured excess weld metal = 3.5 mm c iS measored excess weld metal = 4.5 mm. iS measured excess weld metal = 5.5 mm. D.Welding Inspection : Multiple Choice Questions Paper 2 (Rev. 2) 2s 20. Please return this paper unmarked A carbon manganese 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.... An increased risk of hydrogen cracking An increase risk of solidification cracking Lower values of HAZ toughness Higher values of HAZ hardness pop> ication test weld is a “The first procedure that is prepared for a Weld Procedure Quali pws wes, WPOR WPAR cope ‘Transfer of material identification by hard stamping is sometimes not allowed for high integrity applications because AL itis to slow B. —itcanbe safety hazard C.— Wmay be damaging to the material D. — Allofthe above ‘When welding thin plate distortion can be minimized by... using back-step welding minimizing weld volume using bridge tacks allof the above pop Which of the following would be considered to be high Heat Input welding? A. 350mm B58 )/mm C38. D. 5.0K/mm Initiation of a TIG arc by using a High Frequency a High Frequency spark may not be allowed because. A. Trofteneauses rungstea inclusions B. It can damage electronic equipment C._Itisan electrical safety hazard D. _Itoften eauses stopistart porosity TH Norh, Muosroush Pages ofpeaes §Limited welding position (FLAT & HOPIZONTAL} Run in & run off plates may be required. Wire feed speed is adjusted automatically io equalize the rate of meiting of filler wire to keep the arc den: ‘ant, (Control pane!) Advantages High utilization of electrode wire ecloiking/ Welding helmet Weld pucile is subr:siged, eliminating the need for prov Little or no fume Disadvantages High heat inpur that could be detrimental to some base Wsetals Weld puddle not visible. ‘Type of flux used for SAW 1. Fused 12. Agetomerated ins alloving elements, ete. Th- Mux also called neutral type flux, no alloying | Agglomerated Mun cen: clements, deoxidizing or iytizing agenis are | deoxidizing agent and ionizing added to the flux. | Itis a basie type Mux Itis a ore!nary rutile tvreflux his light grey in color It is Black ¢ Trnwn in color ar Very darle (| Blokish gray ) | | 1t absorbs moisture, therefore preheating is required Athos a spherical shape, Ithas a flakey shape, Glass like appearance, Moisture resistin. therfore mo pchesing | sves best nechanial prope | End of the shift on daily basis to be removed from It is used for General purpose similar to rutile | the hopper 0 pieveat wacktute tbesiptise electrodesOther Points The process 1s a Nat are (constant voll Inere ew active yas shitiding gas process. ti as ¢ semi auromane /Tully amiomanic welding pro 60 S008, . Deposition rate 1-10 Kghr (2-201bihry Mange of thickness Dip transfer & pulsed arc 0.Smun (0,020 inch) upwards Spray transfer 6mm (1/4 inch) upwards. ‘Type of joints All welding joints, including spot welds. Welding position Dip trans fer & pulsed are - all position, ey Spray transfer + flat (T-joints only HV.) and with Aluminum spray transfer ean be used in all pesitions, Access Fair Portability Pair Advantages: process. Thin to thick materials can be welded Fast weld Disadvar raves Root & side wall lack of fusion, ea can't be 5 n on radiograph, Shielding gas is sensitive to wind and drat, Adu: Deposition rate is high, 2. Costs are low because there is less electrode waste, no shay removal and welder downelime due to changing electrode is less compared to SMAW or GTAW. 3. Mis very versatile (all position process for Carbon, Low alloy and Stainless steels) Disadvantages 1. Cost af machinery. shielding yas and maintenanee is high, 2. Accessibility to the welding is restrictive because of the size nf ths gu. 2. Shi Idling gas is sensitive w wind and drafts, 4. ‘The length of the welding lead (cable) is restictive. 5 ‘Phe eqir pment is not portable as SAW.WELDING INSPECTION, STEELS - WIS 5 RMICQ.002) HOICE QUESTION Name Answer all ques 1 BS499 Pan Il communicates by the use of symbols the type of join preparation io be used. Listed / below are four symbols: whieh ofthese incieales ihe cepll af pensrauian of the weld req te join? ats that a weld has 10 bs finished Mush on the ether’ 2 Which of the following symbols would sx side of the weld? A ey 2 : D 3. Whatowe functions ws ar eoumoe uf enable = sable a tobe etisbhshed Are Volige Comers Wire! Electrode feed rate ome > Metal burn-alt rie