CSWIP 3.

1 – Welding Inspector
WIS 5
APPENDICES

Training and Examination Services

Granta Park, Great Abington
Cambridge CB21 6AL
United Kingdom

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 Chapter 3.1 Practical Explanation

Rev March 2023

Prelims Copyright © TWI Ltd
 Practical
explanation

1
Copyright © TWI Ltd 2019

How to assess welding imperfections

Obviously, you have to identify what they are.

Then you need to sentence them against an

acceptance criteria.

Some acceptance criteria have differing levels to

assess against depending on the structure being
built.

Therefore, a nuclear power station would have much

more stringent levels than a digger bucket.
2
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TWI acceptance criteria

The TWI acceptance criteria has three levels of
acceptance for welding imperfections. Group A
being the most stringent with Group C being the
least stringent.
Category Type
Defect Remarks Group A Group B Group C
Type

In the exercises that follow, you will be asked to categorise and sentence welds
to differing levels.

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1
 TWI acceptance criteria
The example below shows the differing acceptance
levels for various imperfections across the groups A
to C. Note how the acceptance becomes less
stringent for any given imperfection A to C.

Category Type
Defect Remarks Group A Group B Group C
Type
Excess weld metal Excess weld metal above
Max 2mm Max 3mm Max 5mm
(A) the parent plate surface
Weld metal below the
Under fill (B) surface of the parent Not permitted Not permitted 5mm in length
material
The length of the inclusion The length of the inclusion
Non metallic inclusions in
shall not exceed 10mm shall not exceed 20mm
Slag/silica inclusions the weld metal or
Not permitted continuously or intermittent. continuously or intermittent.
(C) between the weld metal
Accumulative totals shall not Accumulative totals shall not
and parent metal
exceed 10mm exceed 20mm

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Copyright © TWI Ltd 2019

TWI acceptance criteria

Category Type
Defect Type Remarks Group A Group B Group C
Excess weld metal above the
Excess weld metal (A) Max 2mm Max 3mm Max 5mm
parent plate surface

Weld metal below the surface of

Under fill (B) Not permitted Not permitted 5mm in length
the parent material

The length of the inclusion shall not The length of the inclusion shall not
Non metallic inclusions in the
exceed 10mm continuously or exceed 20mm continuously or
Slag/silica inclusions (C) weld metal or between the weld Not permitted
intermittent. Accumulative totals shall intermittent. Accumulative totals shall
metal and parent metal
not exceed 10mm not exceed 20mm

No sharp indications, smooth blend No sharp indications, smooth blend The length of any undercut shall not
required. The length of any undercut required. The length of any undercut exceed 25mm continuously or
shall not exceed 5mm continuously or shall not exceed 10mm continuously or intermittent. Accumulative totals shall
A groove melted into the parent intermittent. Accumulative totals shall intermittent. Accumulative totals shall not exceed 25mm. Max depth 3mm
metal, at the toes of the weld not exceed 5mm. Max depth 1mm for not exceed 10mm. Max depth 1.5mm for for the weld face.
Undercut (D)
metal, root or adjacent weld the weld face. the weld face. Root undercut as above
metal Root undercut not permitted. Root undercut not permitted.

There should be no part of the

No stop starts to be within 30mm of No stop starts to be within 20mm of No stop starts to be within 10mm of
Stop/Starts (E) previous weld crater showing at
each other each other each other
the re-start

Surface breaking lack of side wall

Incomplete fusion between the Surface breaking lack of side wall fusion,
Lack of sidewall Fusion fusion, lack of inter run fusion
weld metal and base metal. lack of inter run fusion continuous or
Laps Not permitted continuous or intermittent not to
Incomplete fusion between weld intermittent not to exceed 15mm.
Cold laps (F) exceed 15mm. Accumulative totals
metal (lack of inter run fusion). Accumulative totals not to exceed 15mm
not to exceed 15mm

Damage to parent metal or weld

metal from a touch down of
Arc strikes (G) Not permitted One permitted Two permitted
electrode or other electrical
source
One stray tack welds permitted
No stray tack welds permitted No stray tack welds permitted
Damage to parent metal or weld Parent metal must be smoothly
Parent metal must be blended Parent metal must be blended smoothly
Mechanical damage (H) metal excluding any hard blended
smoothly Max depth 1mm
stamping and pop marks Max depth 1.5mm
Max depth 0.5mm Only in one location
Max two locations

Excess weld metal above the base

Penetration (I) Max height 2mm Max height 3mm Max height 4mm
material in the root of the joint
The absence of weld metal in the
Lack of root penetration (J) root area, two root faces showing Max length 5mm Max length 10mm Max length 15mm

No fusion on one root face Max 25mm continuous or

Lack of root fusion (K) Max 4mm Continuous or intermittent Max 10mm continuous or intermittent
intermittent
Burn through (L) Collapse of the weld root Not permitted One area permitted Two areas permitted
Weld metal below the surface of
Root concavity (M) both parent metals Not permitted Max 10mm length Max 20mm length

5
Copyright © TWI Ltd 2019

Questions that are asked

Below are the three questions that are asked, the same
three questions are asked on each segment:-

1. Which imperfections are identifiable on the sample.

2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C

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2
 Questions that are asked
You are required to inspect both the face and root
side of the segments.

1. Which imperfections are identifiable on the

sample.

This question is simply asking you to identify the

imperfections on the sample from the 13 listed in
the acceptance criteria.

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Imperfections
Imperfections that could be listed:-
Defect Type
Excess weld metal (A)
Under fill (B)
Slag/silica inclusions (C)
Undercut (D)
Stop/Starts (E)
Lack of sidewall Fusion
Laps
Cold laps (F)
Arc strikes (G)
Mechanical damage (H)
Penetration (I)
Lack of root penetration (J)
Lack of root fusion (K)
Burn through (L)
Root concavity (M)

The imperfections are identified by letters A to M

8
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How to answer questions

1. Which imperfections are identifiable on the sample.

1.

2.

3.

The question is asking you not to accept or reject the imperfection, just to identify it’s
there.

Copyright © TWI Ltd 2019

3
 How to answer questions
2. Which imperfections are not acceptable to group A

A B C D E F G H I J K L M

X X X X X X x X X
1.

X X X x X x X
2.

3.

The question is now asking you which imperfections are not acceptable to category A the
most stringent.

10
Copyright © TWI Ltd 2019

How to answer questions

3. Which imperfections are not acceptable to group C

A B C D E F G H I J K L M

1. X X X X X X X X

2. X X X X X

3. X X

The question is now asking you which imperfections are not acceptable to category C the
least stringent.

11
Copyright © TWI Ltd 2019

Scoring your answers

You are required to get 70% of correct answers.

However, marks will be deducted for incorrect

answers.

Therefore, ensure your x in the box is for a purpose.

Indiscriminate use of X’s could significantly lower
your score!

12

Copyright © TWI Ltd 2019

4
 2.21 Practical

Revision March 2023 Copyright © TWI Ltd

 Defect Remarks Group A Group B Group C
Type
Excess weld metal
Excess weld
above the parent Max 2mm Max 3mm Max 5mm
metal (A)
plate surface
Weld metal below
Under fill (B) the surface of the Not permitted Not permitted 5mm in length
parent material
The length of the The length of the
Non metallic
inclusion shall not inclusion shall not
inclusions in the
exceed 10mm exceed 20mm
Slag/silica weld metal or
Not permitted continuously or continuously or
inclusions (C) between the weld
intermittent. intermittent.
metal and parent
Accumulative totals shall Accumulative totals
metal
not exceed 10mm shall not exceed 20mm
No sharp indications, No sharp indications, The length of any
smooth blend required. smooth blend required. undercut shall not
The length of any The length of any exceed 25mm
undercut shall not undercut shall not continuously or
A groove melted
exceed 5mm exceed 10mm intermittent.
into the parent
continuously or continuously or Accumulative totals
metal, at the toes of
Undercut (D) intermittent. intermittent. shall not exceed
the weld metal, root
Accumulative totals Accumulative totals shall 25mm. Max depth
or adjacent weld
shall not exceed 5mm. not exceed 10mm. Max 3mm for the weld face
metal
Max depth 1mm for the depth 1.5mm for the and the root.
weld face. weld face.
Root undercut not Root undercut not
permitted. permitted.

There should be no
No stop starts to be No stop starts to be No stop starts to be
Stop/Starts part of the previous
within 30mm of each within 20mm of each within 10mm of each
(E) weld crater showing
other other other
at the re-start
Surface breaking lack of Surface breaking lack
Incomplete fusion
side wall fusion, lack of of side wall fusion, lack
Lack of between the weld
inter run fusion of inter run fusion
sidewall metal and base
continuous or continuous or
Fusion metal. Incomplete Not permitted
intermittent not to intermittent not to
Laps fusion between weld
exceed 15mm. exceed 15mm.
Cold laps (F) metal (lack of inter
Accumulative totals not Accumulative totals not
run fusion).
to exceed 15mm to exceed 15mm
Damage to parent
metal or weld metal
Arc strikes (G) from a touch down Not permitted One permitted Two permitted
of electrode or other
electrical source
No stray tack welds No stray tack welds One stray tack welds
Damage to parent
permitted permitted permitted
metal or weld metal
Mechanical Parent metal must be Parent metal must be Parent metal must be
excluding any hard
damage (H) blended smoothly blended smoothly smoothly blended
stamping and pop
Max depth 0.5mm Max depth 1mm Max depth 1.5mm
marks
Only in one location Only in one location Max two locations
Excess weld metal
above the base
Penetration (I) Max height 2mm Max height 3mm Max height 4mm
material in the root
of the joint
The absence of weld
Lack of root metal in the root
Max length 5mm Max length 10mm Max length 15mm
penetration (J) area, two root faces
showing
Lack of root No fusion on one Max 4mm Continuous Max 10mm continuous or Max 25mm continuous
fusion (K) root face or intermittent intermittent or intermittent
Burn through Collapse of the weld
Not permitted One area permitted Two areas permitted
(L) root
Weld metal below
Root concavity
the surface of both Not permitted Max 10mm length Max 20mm length
(M)
parent metals

Rev March 2023

Prelims 1 Copyright © TWI Ltd
 Plate Segment Plate Segment
1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

 Plate Segment Plate Segment
1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

 Plate Segment Plate Segment
1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

Plate Segment Plate Segment

1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample

2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A

3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

Copyright © TWI Ltd Copyright © TWI Ltd

 Plate Segment Plate Segment
1. Which imperfections are identifiable on the sample 1. Which imperfections are identifiable on the sample
2. Which imperfections are not acceptable to category A 2. Which imperfections are not acceptable to category A
3. Which imperfections are not acceptable to category C 3. Which imperfections are not acceptable to category C

A B C D E F G H I J K L M A B C D E F G H I J K L M

1 1

2 2

3 3

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Copyright © TWI Ltd
 Chapter 4.1 Work Pack Explanation

Rev March 2023

Prelims Copyright © TWI Ltd
 3.1 Work
package
WPS & WQT

Copyright © TWI Ltd 2015

The scenario
You are required to oversee the completion of a
fabrication shown on drawing 4. This will require
establishing that the correct welder qualifications
and WPS(s) are being used.

2
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The scenario
For this exercise you need to make reference to the
following documents:
WPS`S 7,9,17 and 25
Welder qualifications
Q1D4,Q2D4,Q3D4 and Q4D4
Drawing train 1
You will also need the 20 questions associated with
this exercise.
Please turn to the work pack section in the students
work book.
3
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 4.2 Work pack questions
MULTI CHOICE QUESTIONS and DRAWING Training One
Inspection scenario
You are required to oversee the completion of a fabrication shown on drawing 4. This will require establishing that the correct
welder qualifications and WPS(s) are being used and also inspecting before, during and after welding.

1. Weld progression on WPS 9 is stated as uphill, which of the following welding positions would this be according to EN
standards?

A. PF
B. PG
C. PD
D. PC

2. On WPS 9 the electrode covering states basic covering, is the welder qualification test certificate Q1D4 covered for
basic electrodes?

A. Yes, he can use rutile electrodes also

B. Yes he can use basic electrodes only
C. No, he can only use rutile electrodes
D. No, he can only use cellulosic

3. On welder qualification Q1D4, the electrode covering is stated as H10, what does this mean?

A. H10 is classed as 10grms/100ml of hydrogen in the weld

B. H10 is classed as high hydrogen level
C. H10 is classed as 10ml/100grms of hydrogen in the weld metal
D. H10 can never be baked

4. On WPS 7, which of the following tungstens would not normally be used?

A. Thoriated
B. Zirconiated
C. Ceriated
D. Lanthiated

5. Can welder qualification Q2D4 be used for a multi layer fillet weld?

A. Yes, but only two layers

B. Yes, as long as you stay within the parameters
C. No, only single because of the size
D. No, only single layer allowed as stated on the drawing

6. On WPS 7, there is no thickness given for the plate. What would be the minimum and maximum leg length for the fillet
weld?

A. 2.9 to 6mm
B. 2 to 4mm
C. 1.5 to 6mm
D. 3 to 12mm

Rev March 2023

Prelims Copyright © TWI Ltd
 7. Is the welder qualification Q4D4 qualified to weld with WPS 17.

A. No, thickness and diameter are covered

B. Yes, they use the same filler material
C. Yes, but only up to a certain thickness
D. No, base materials are not the same

8. On WPS 17, what welding positions is it qualified too?

A. All positions listed are correct

B. Only three positions are correct
C. Only two are correct
D. Only one position are two

9. Can WPS 17 be used on a 25mm thick plate?

A. No problem, this thickness is covered

B. The WPS does not cover plate
C. The thickness is out of the range of approval
D. A maximum of five layers in PB position will complete the joint

10. From the four WPS(s), what is the most suitable WPS for joint 10 on
drawing Train 1?

A. WPS 7
B. WPS 9
C. WPS 17
D. WPS 25

11. If the wall thickness of P1 is increased to 20mm, can we use WPS 17

in combination with welder qualification Q4D4 for joint 1 on drawing Train 1?

A. No, it is covered by the WPS but not the welder qualification

B. Yes, both cover this joint
C. No, they do not cover this joint
D. No, WPS does not cover but welder qualification does

12. WPS 17 is being used to weld joint 2 with a gas mixture of 84% argon and 16% CO2, what would be the effect on the
weld profile.

A. Makes the weld wider

B. Increases the penetration
C. Increases heat input
D. Decrease in penetration

13. An interpass temperature of 300°C was taken from joint 2 drawing train 1 using WPS 9. What would be the effect of
this and what type of action would you take?

A. Nothing, it has no influence

B. Stop the welding because there is a risk of high hardness in HAZ.
C. Stop welding because of a risk of low toughness in the HAZ
D. Stop welding and ask the welder to cool the weld down with water

Rev March 2023

Prelims Copyright © TWI Ltd
 14. What would happen to the flange if you welded joint 10 as stated on drawing Train 1?

A. It would require some type of distortion prevention in place

B. Distortion will not be a problem
C. Use strong backs prevent distortion
D. Pre set the flange to prevent distortion

15. Changing to DC+ for the root on WPS 9 joint 1, drawing Train 1. What would be the effect of this change
and do you allow it?

A. Yes, allow no effects

B. No, don’t allow this there is a risk of burn through
C. No, there is a risk of lack of root fusion
D. Yes, it only has positive effects

16. Can welder qualification Q3D4, with WPS 25, be used to weld joint 8 on drawing Tran 1?

A. Yes no problem both are covered

B. No, welder qualification is incorrect but the WPS is correct
C. No, WPS is incorrect but welder qualification covers
D. Yes, there is no influence all welding positions are covered

17. Considering all of the 4 WPS(s), which one would most likely use backing?

A. WPS 7
B. WPS 9
C. WPS 17
D. WPS 25

18. On WPS 25 what will be the minimum and maximum heat input?

A. 0.5 to 3.1 kJ per mm

B. 1.2 to 3.8 kJ per mm
C. 1.3 to 3.1 kJ per mm
D. 1.5 to 1.6 kJ per mm

19. On WPS 17 what will be the minimum and maximum arc energy?

A. 1.3 to 4.2 kJ per mm

B. 0.6 to 4.2 kJ per mm
C. 1.6 to 3.3 kJ per mm
D. 0.5 to 3.3 kJ per mm

20. Welder qualification Q1D4, on joint 8 drawing train 1 is the welder qualified to weld this joint in the fixed
position?

A. Yes, he is qualified for all positions

B. No, not qualified as the diameter is incorrect
C. Yes, he is qualified by pipe diameter
D. No, diameterer is qualified but position is incorrect

Rev March 2023

Prelims Copyright © TWI Ltd
 Welder Qualification Test Certificate
(ISO 9606-1: 2017)
Number Q1D4
Designation: ISO 9606-1,111,T,BW,FM1,B,s5.5,t5.5,D60.32,H-L045,ss,nb
Welding Procedure Examining Body: TWI CL
Specification Reference No. Reference No:
Welders Name Joe Bloggs
Identification
Method of Identification:
Photograph
Date and Place of Birth: 01/10/1996
(if required)
Employer:
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) MMA 111 MMA 111
Transfer Mode N/A N/A
Product Type (plate or pipe) (T) Pipe (T) Pipe & (P) Plate
Type of Weld (BW) Butt Weld (BW) Butt Welds Only
Parent Material S275JR Non Essential Variable (Any)
Filler Materials Group(s) FM1 FM1 & FM2
Filler Material (designation) EN ISO 2560-A; E 42 4 B 12 H10 A, RA, RB, RC, RR, R & B
Shielding Gas N/A N/A
Auxiliaries N/A N/A
Type of Current and Polarity DC + Non Essential Variable (Any)
Material Thickness (mm) 5.54mm 3.0mm to 11.08mm
Deposited Thickness (mm) 5.54mm 3.0mm to 11.08mm
Outside Pipe Diameter (mm) 60.32mm ≥ 30.16mm
Welding Positions H-L045 All Except Vertical Down
Weld Details ss nb ss mb, ss nb, ss gb, ss fb & bs
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) Not Performed
See Test Report No:

Type of Test Performed and Acceptable Not Tested Name & Signature of Engineer
Visual Testing Acceptable
Radiographic Testing Acceptable Name
Inspecting Authority
Fracture Test Not Tested TWI Certification Limited
Bend Test Not Tested
Date of Issue: 20/05/2019
Notch Tensile Test Not Tested
Location: Middlesbrough
Macroscopic Not Tested Validity of Qualification: 11/05/2022
Examination

Date of Welding: 12/05/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 11/05/2022 on 9.3 b) xxxxxxxxxxx on 9.3 c) xxxxxxxxxxx

Rev March 2023

Prelims Copyright © TWI Ltd
 Welder Qualification Test Certificate
(ISO 9606-1:2017)
Number Q2D4
Designation: ISO 9606-
1,141,P,FW,FM1,S,t6.0,PB,ml
Welding Procedure Examining Body: TWI CL
Specification Reference No. Reference No:
Welders Name Joe Bloggs
Identification
Method of Identification:
Photograph
Date and Place of Birth: 01/10/1996
(if required)
Employer:
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) 141 TIG TIG 141/142/143/145
Transfer Mode N/A N/A
Product Type (plate or pipe) (P) Plate (T) Tube/Pipe (P) Plate
Type of Weld (FW) Fillet Weld (FW) Fillet Welds only
Parent Material S275JR Non Essential Variable (Any)
Filler Materials Group(s) FM1 FM1 & FM2
Filler Material (designation) EN 636-A; W 42 3 W3Si1 S&M
Shielding Gas ISO 14175-I1 Ar 99.9% Non Essential Variable (Any)
Auxiliaries N/A N/A
Type of Current and Polarity DC - VE Non Essential Variable (Any)
Material Thickness (mm) 6mm ≥ 3.0mm
Outside Pipe Diameter (mm) N/A Pipe ≥ 75mm rotated PA Only ≥ 500m
Fixed
Welding Positions PB PA & PB
Weld Details ss mb ss mb & bs
Multi-layer/Single Layer ml (Multi-Layer) ml & sl (Multi & Single-Layer)

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) Not Performed

See Test Report No:

Type of Test Performed and Not Tested Name & Signature of Engineer
Acceptable
Visual Testing Acceptable
Certifying Authority
Radiographic Testing Not Tested TWI Certification Limited
Fracture Test Acceptable
Date of Issue: 04/04/2019
Bend Test Not Tested
Location: Middlesbrough
Notch Tensile Test Not Tested Validity of Qualification:
Macroscopic Not Tested 30/03/2022
Examination

Date of Welding: 01/04/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 30/03/2022 on 9.3 b) xxxxxxxxxxxxxxx on 9.3 c) xxxxxxxxxxxxxxx

Rev March 2023

Prelims Copyright © TWI Ltd
 Welder Qualification Test Certificate
(ISO 9606-1:2017)
Number Q3D4
Designation: EN ISO 9606-1,136,T,BW,FM1,s7.11,t7.11,H-L045,ss nb
Welding Procedure Examining Body: TWI CL
Specification Reference No. WPS Reference No:
Welders Name John Smith
Identification JS
Method of Identification: Initials
Photograph
Date and Place of Birth: 18/08/76
(if required)
Employer: Private
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) 136 FCAW 136 FCAW
Transfer Mode Spray Spray
Product Type (plate or pipe) (T) Pipe (T) Pipe & (P) Plate
Type of Weld (BW) Butt weld (BW) Butt Welds Only
Parent Material EN 10025-2 (S355J2) Grp 1.2 Non Essential Variable (Any)
Filler Materials Group(s) FM 1 FM 1 & FM 2
Filler Material (designation) EN ISO 17632-A T 42 4 B C 2 H5 R, P, V, W, Y, Z & B
Shielding Gas ISO 14175-M21 Ar80 % 20% C02 Non Essential Variable (Any)
Auxiliaries N/A N/A
Type of Current and Polarity DC + Non Essential Variable (Any)
Material Thickness (mm) 7.11mm 3.0mm to 14.22mm
Deposited Thickness (mm) 7.11mm 3.0mm to 14.22mm
Outside Pipe Diameter (mm) 168.3mm ≥ 84.15mm
Welding Positions H-L045 All Except Vertical Down
Weld Details ss nb ss mb, ss nb, ss gb, ss fb & bs
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) N/A

See Test Report No:

Type of Test Performed and Not Tested Name & Signature of Engineer
Acceptable
Visual Testing Acceptable
Inspecting Authority
Radiographic Testing Acceptable TWI Certification Limited
Fracture Test Not Tested
Date of Issue: 10/08/2019
Bend Test Acceptable
Location: Middlesbrough
Notch Tensile Test Not Tested Validity of Qualification:
Macroscopic Not Tested 01/08/2022
Examination

Date of Welding: 02/08/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 01/08/2022 on 9.3 b) on 9.3 c)

Rev March 2023

Prelims Copyright © TWI Ltd
 Welder Qualification Test Certificate
(ISO 9606-1:2017)
Number Q4D4
Designation: EN ISO 9606-1,135,T,BW,FM1,s7.11,t7.11,H-L045,ss nb
Welding Procedure Examining Body: TWI CL
Specification Reference No. WPS Reference No:
Welders Name John Smith
Identification JS
Method of Identification: Initials
Photograph
Date and Place of Birth: 18/08/76
(if required)
Employer: Private
Code/Testing Standard: BS EN ISO 9606-1:2017
Job Knowledge: Not Tested
Test Piece Range of Qualification
Welding Process(es) 135MAG 135 / 138 MAG
Transfer Mode Dip & Spray Dip, Globular and Spray
Product Type (plate or pipe) (T) Pipe/Tube (T) Pipe/Tube & (P) Plate
Type of Weld (BW) Butt weld (BW) Butt Welds Only
Parent Material EN 10025-2 (S355J2) Grp 1.2 Non Essential Variable (Any)
Filler Materials Group(s) FM 1 FM 1 & FM 2
Filler Material (designation) EN ISO 14341-A G 46 4 M 3Si1 S&M
Shielding Gas ISO 14175-M14 Ar93 % 5% C02 2% Non Essential Variable (Any)
02
Auxiliaries N/A N/A
Type of Current and Polarity DC + Non Essential Variable (Any)
Material Thickness (mm) 7.11mm 3.0mm to 14.22mm
Deposited Thickness (mm) 7.11mm 3.0mm to 14.22mm
Outside Pipe Diameter (mm) 168.3mm ≥ 84.15mm
Welding Positions H-L045 All Except Vertical Down
Weld Details ss nb ss mb, ss nb, ss gb, ss fb & bs
Multi-layer/Single Layer ml sl & ml

Supplementary Fillet Weld Test (completed in conjunction with a butt weld) N/A

See Test Report No:

Type of Test Performed and Not Tested Name & Signature of Engineer
Acceptable
Visual Testing Acceptable
Inspecting Authority
Radiographic Testing Acceptable TWI Certification Limited
Fracture Test Not Tested
Date of Issue: 10/08/2019
Bend Test Acceptable
Location: Middlesbrough
Notch Tensile Test Not Tested Validity of Qualification:
Macroscopic Not Tested 01/08/2022
Examination

Date of Welding: 02/08/2019

Revalidation Valid Until Revalidation Valid Until Revalidation Valid Until

on 9.3 a) 01/08/2022 on 9.3 b) on 9.3 c)

Rev March 2023

Prelims Copyright © TWI Ltd
 WPQR No 7 WPS No 7

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING
a = 2.1 - 4.2
FILLET WELD SEQUENCE ONE SIDE ONLY!

POSITION
MATERIAL SPEC. Carbon Steel POSITION QUALIFIED PA, PB, PD & PF
BASE METAL

TYPE or GRADE Plate PROGRESSION All except vertical down

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°c When Applicable

PRE - HEAT
THICKNESS RANGE (mm) 3.0 - 12.0 APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE N/a MAX INTERPASS TEMP 250°c

FILLER METAL

TRADE NAME ROOT ER70S-6 or A18 METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER N/a FIT UP METHOD Tacks

TECHNIQUE

TRADE NAME CAP N/a STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14175 - I1 CLEANING METHOD Wire Brushing

GAS/FLUX

COMPOSITION 99.9% Argon SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min 10 to 12 DIP N/a

DIAMETER 10 to 12mm GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH N/a SPRAY N/a

TUNGSTEN TYPE & DIA Ceriated 1.6 or 2.4mm PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 1 TIG (141) 1.6 or 2.4 A18 DC - VE 75 - 120 9 to 12 N/a 80 - 150 N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:

Rev March 2023

Prelims Copyright © TWI Ltd
 WPQR No 9 WPS No 9

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE
60 - 70 Deg Included Angle

* Runs as required see notes

1-2mm Root Face

2 - 4mm Root Gap

POSITION
MATERIAL SPEC. Carbon Steel POSITION QUALIFIED All Except PG and J-L045
BASE METAL

TYPE or GRADE Pipe PROGRESSION Uphill

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°c

PRE - HEAT
THICKNESS RANGE (mm) *5.485 - 21.94 APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE Pipe with dia. ≥84.15mm MAX INTERPASS TEMP 250°c
FILLER METAL

TRADE NAME ROOT E7016 or E7018 (Basic) METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER E7016 or E7018 (Basic) FIT UP METHOD Tacks and strongbacks
TECHNIQUE

TRADE NAME CAP E7016 or E7018 (Basic) STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 N/a CLEANING METHOD Wire Brushing

GAS/FLUX

COMPOSITION N/a SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min N/a DIP N/a

DIAMETER N/a GLOBULAR N/a

NOZZLE

WIRE STICKOUT LENGTH N/a SPRAY N/a

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 Root MMA (111) 2.5mm E7016/18 DC - VE 75 - 90 20 - 22 N/a N/a N/a
1 Fill MMA (111) 2.5mm E7016/18 DC + VE 80 - 95 20 - 22 N/a N/a N/a
**1 Fill MMA (111) 3.25mm E7016/18 DC + VE 90 - 120 24 - 26 N/a N/a N/a
1 Fill MMA (111) 3.25mm E7016/18 DC + VE 90 - 120 24 - 26 N/a N/a N/a
**1 Cap MMA (111) 3.25mm E7016/18 DC + VE 90 - 120 24 - 26 N/a N/a N/a
1 Cap MMA (111) 2.5mm E7016/18 DC + VE 75 - 90 22 - 24 N/a N/a N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

* Number of runs dependent on material thickness

** Size of MMA Electrode dependent on material thickness

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:

Rev March 2023

Prelims Copyright © TWI Ltd
 WPQR No 17 WPS No 17

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE
60 - 70 Deg Included Angle Side 1
4 5
3
2
2-4mm Root Face
1

1 to 2mm Root Gap

POSITION
MATERIAL SPEC. Carbon Steel POSITION QUALIFIED PA, PC, PD & PF
BASE METAL

TYPE or GRADE Pipe PROGRESSION All except vertical down

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°c

PRE - HEAT
THICKNESS RANGE (mm) 5.485 - 21.94 APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE Pipe with dia. ≥84.15 MAX INTERPASS TEMP 150°c
FILLER METAL

TRADE NAME ROOT ER70S-6 or A18 METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME FILLER ER70S-6 or A18 FIT UP METHOD Tacks and strongbacks
TECHNIQUE

TRADE NAME CAP ER70S-6 or A18 STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14175 - M21 CLEANING METHOD Wire Brushing
GAS/FLUX

COMPOSITION 80% Ar 20% C02 SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min 12 to 15 DIP Yes

DIAMETER 15 to 20mm GLOBULAR Yes

NOZZLE

WIRE STICKOUT LENGTH As Required SPRAY Yes

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 1 MAG (135) 1.2 A18 DC + VE 120 - 150 18 - 22 N/a 100 - 180 N/a
1 Fill MAG (135) 1.2 A18 DC + VE 150 - 280 22 - 30 N/a 120 - 300 N/a
1 Cap MAG (135) 1.2 A18 DC + VE 150 - 280 22 - 30 N/a 120 - 300 N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:

Rev March 2023

Prelims Copyright © TWI Ltd
 WPQR No 25 WPS No 25

SPECIFICATIONS : ISO 15614-1: 2017

WELD PREP DESIGN TYPICAL WELDING SEQUENCE
60 - 70 Deg Included Angle

5 4

2 3

1-2mm Root Face 1

2 to 4mm Root Gap

POSITION
MATERIAL SPEC. Carbon Steel POSITION QUALIFIED PA, PB & PC
BASE METAL

TYPE or GRADE Pipe PROGRESSION All except vertical down

ISO 15614-1 GROUP No Group 1 MINIMUM TEMPERATURE 15°c When Applicable

PRE - HEAT
THICKNESS RANGE (mm) 5.485 to 21.09 APPLICATION METHOD Gas Torch When Applicable

DIAMETER RANGE Pipe with dia. ≥84.15 MAX INTERPASS TEMP 250°c
FILLER METAL

TRADE NAME PASS 1 ER70T1 (Flux Cored Wire) METHOD OF MEASUREMENT Digital Thermometer or Tempilstick

TRADE NAME PASS 2 ER70T1 (Flux Cored Wire) FIT UP METHOD Tacks
TECHNIQUE

TRADE NAME PASS 3 ER70T1 (Flux Cored Wire) STRINGER/WEAVE BEAD Stringer

TYPE OF SHIELDING SIDE 1 ISO 14715 - M21 CLEANING METHOD Wire Brushing
GAS/FLUX

COMPOSITION 80% AR 20% C02 SECOND SIDE TREATMENT N/a

MODE OF TRANSFER

FLOW RATE L/Min 12 to 18 DIP Yes

DIAMETER 15 to 20mm GLOBULAR Yes

NOZZLE

WIRE STICKOUT LENGTH As Required SPRAY Yes

TUNGSTEN TYPE & DIA N/a PULSE N/a

ELECTRICAL WELD HEAT

SIDE PASS WELDING DIA CODE CHARACTERISTICS R.O.L. SPEED INPUT
No PROCESS MM REF POLARITY AMPS ARC (mm) mm/Min KJ/mm²
AC/DC RANGE VOLTS
1 Root FCAW (136) 1.2 ER70T1 DC + 160 - 300 24 - 32 N/a 150 - 350 N/a
1 Fill FCAW (136) 1.2 ER70T1 DC + 160 - 300 24 - 32 N/a 150 - 350 N/a
1 Cap FCAW (136) 1.2 ER70T1 DC + 160 - 300 24 - 32 N/a 150 - 350 N/a

ISSUED BY TWI: Notes:

1) Weld area to be cleaned of rust etc for a minimum of 25mm each side
of the joint configuration using a grinder/wire brush as required.

2) Tack welds and strongbacks where necessary.

CONSUMABLE HANDLING:
As per manufacturers recommendation
DATE:

Rev March 2023

Prelims Copyright © TWI Ltd
 W10

TRAIN 1

200 10mm 400 10 10

200 10mm 400 10 10
200 10mm 10 10
200 10mm 10 10
200 10mm 10 10
200 10mm
 HOMEWORKS

Chapter 5

Rev March 2023

Prelims Copyright © TWI Ltd
CSWIP 3.1 Homework : Leading Multiple Choice Questions
Paper 1

Name: ……………………………….…………………………. Date: ……………………

1 Which is the best destructive test for showing lack of sidewall fusion in a 25mm
thickness butt weld?

a Nick break.
b Side bend.
c Charpy impact.
d Face bend test.

1a With reference to the previous question and the correct answer, what type of test is
this?

a Qualitative
b Tentative
c Quantitative
d Sensitive

2 Which of the following would be cause for rejection by most fabrication standards
when inspecting fillet welds with undercut, a small amount of?

a Depth.
b Length.
c Width.
d Sharpness.

2a With reference to the previous question, what would be the most likely cause of
undercut?

a High inductance
b High wire feed speed
c Low inductance
d Low voltage

3 The European Standard for NDE of fusion welds by visual examination is:

a EN 15614.
b EN 2560.
c EN 9606.
d EN 17637.
3a With reference to the previous question, two of the standards are closely linked to
each other, which are they?

a a and b
b b and c
c a and c
d a and d

4 When visually inspecting the face of a finished weld which of the following flaws would
be considered the most serious:

a Excess weld metal height.

b Start porosity.
c Spatter.
d Arc strike.

4a With reference to the previous question and the correct answer, why is it considered
so?

a It looks bad
b It’s a hard spot
c Its lack of fusion
d It’s a volumetric defect

5 Which of the following is a planar imperfection?

a Lack of sidewall fusion.

b Slag inclusion.
c Linear porosity.
d Root concavity.

5a With reference to the previous question and the correct answer, how could this defect
be caused?

a Amperage to high
b Voltage too high
c Amperage too low
d Gas flow rate too low

6 A fillet weld has an actual throat thickness of 8mm and a leg length of 7mm, what is
the excess weld metal?

a 2.1mm.
b 1.8mm.
c 3.1mm.
d 1.4mm.
6a With reference to the previous question and the correct answer, if this excess weld
metal was removed the fillet would be a?

a Concave fillet weld

b Convex fillet weld
c Mitre
d Undersized fillet weld

7 BS EN 17637 allows the use of a magnifying glass for visual inspection, but
recommends that the magnification is:

a X 2.
b X 2 to x5.
c X 5 to x10.
d Not greater than x20.

7a With reference to the previous question, what likely defect will this help to find?

a Excess weld metal height

b Undercut
c Internal lack of fusion
d Root concavity

8 A WPS may specify a maximum width for individual weld beads (weave width) when
welding CMn steels. If the width is exceeded it may cause:

a Lack of inter-run fusion.

b A reduction in HAZ toughness.
c Lack of sidewall fusion.
d Too low a deposition rate.

8a With reference to the previous question and the correct answer, in what welding
position is this most likely to happen?

a PA
b PB
c PF
d PG

9 In TIG welding a current slope-out device reduces:

a Tungsten spatter.
b Risk of crater cracking.
c Risk of arc strikes.
d Interpass temperature.

9a With reference to the previous question and the correct answer, what other device is
working at the same time?

a Gas flow
b Slope up device
c High frequency
d Pre purge
10 Pipe bores of some materials must be purged with argon before and during TIG
welding to:

a Prevent linear porosity.

b Prevent burn-through.
c Prevent oxidation of the root bead.
d Eliminate moisture pick-up in the root bead.

10a With reference to the previous question and the correct answer, what material would
this pipe be?

a All materials
b Aluminium and stainless steel
c Stainless steel
d Carbon steel and stainless steel

11 According to AWS 2.4 a weld symbol for the other side is placed:

a Above the dashed line.

b Below the dashed line.
c Above the solid line.
d Below the solid line.

11a With reference to the previous question, when is the dashed line removed?

a When the welds are symmetrical

b There is no dashed line
c When it’s a butt weld
d When the fillet welds are different sizes

12 Which of the following elements is added to steel to give resistance to creep at

elevated service temperatures?

a Nickel.
b Manganese.
c Molybdenum.
d Aluminium.

12a With reference to the previous question, what is creep?

a It’s a form of sensitization

b It’s a form of deformation
c It’s a rupture
d It’s a type of corrosion

13 Compound fillet welds:

a Always contain full penetration butt welds.

b Joints which always have combinations of welds made by different welding
processes.
c Combinations between two different weld types.
d All of the above.
13a With reference to the previous question and the correct answer, what would be the
typical bevel angle for a compound fillet weld?

a 30° degrees
b 35° degrees
c 40° degrees
d 50° degrees

14 Welding inspectors:

a Normally supervise welders.

b Are normally requested to write welding procedures.
c Are sometimes requested to qualify welders.
d All of the above.

14a With reference to the previous question, what standard would be used?

a ASME 8
b EN 2650
c EN 9606
d EN 15614

15 In an arc welding process, which of the following is the correct term used for the
amount of weld metal deposited per hour?

a Filling rate.
b Deposition rate.
c Weld deposition.
d Weld duty cycle.

15a With reference to the previous question and the correct answer, how is this measured?

a Kg per mm
b Kg per hour
c A percentage of 10 minutes
d Millilitres per 100 grms of weld
 Drag and Drop

There can be more than one answer to each question

16. A macro examination would be considered?

Options:
• a quantitative test,
• a hardness test,
• a detailed test,
• a qualitative test,
• a destructive test.

17. A Charpy impact specimen, may show which of the following?

Options:

• Brittle failure,
• cyclic failure,
• solidification failure,
• ductile failure,
• plastic failure,
• elastic failure.

18. In bend testing, which of the following is generally NOT done for thin material?

Options:
• Excess weld metal removed,
• 10% radius produced on the longer lengths of the sample,
• excess weld metal not removed, diameter of former 4t of the specimen
thickness,
• bend angle up to 180°.
19. A tensile test was conducted on a specimen 200mm in length. After completion, the
specimen measured 250mm in length. What is the percentage elongation?

Options:
• 20%,
• 25%,
• 30%,
• 15%,
• 18%,
• 16%.

20. When using MPI, the defects are detected at?

Options:
• 180° to the magnetic force, directly between the poles,
• at right angles to the magnetic force,
• 50mm from the poles.

21. Which of the following would a welding inspector be required to do after welding?

Options:
• Check PWHT,
• check pre heat temperature,
• arrange NDT, sentence the weld,
• check dimensions,
• complete report,
• check material certificates.

22. What would be the weld area volume for a 6mm equal leg length fillet weld?

Options:
• 10mm²,
• 18mm²,
• 16mm²,
• 14mm²,
• 12mm²,
• 15mm².
23. Which of the following are used to calculate heat input?

Options:
• Travel speed,
• electrode size,
• polarity,
• voltage,
• gas flow rate,
• “K” factor,
• amperage.

24. Which of the following materials can be welded with the SAW process?

Options:
• HSLA steels,
• stainlsss steel,
• aluminium,
• Duplex,
• CMn steels,
• copper alloys.
 Fill the blank

Add the missing word from the options given

25. Magnification in the range of _ _ _ _ _ _ _ can be used when visually inspecting welds.

Options:
• X2 to X5,
• X5 to X10,
• X3 to X6,
• X8 to X12

26. Too _ _ _ _ _ _ _ _ _ _ _ could cause lack of penetration.

Options:
• Large an electrode,
• much amperage,
• little gas shield,
• large a bevel angle

27. The included angle on _ _ _ _ _ _ _ _ is increased to avoid lack of fusion.

Options:
• Stainless steel,
• HSLA steels,
• CMn steels,
• Aluminium

28. In TIG welding _ _ _ _ _ _ _, tungsten inclusions can occur.

Options:
• Not using the slope up,
• Using a high gas flow rate,
• using a high frequency,
• using alternating current
29. A _ _ _ _ _ _ _ _ _ can cause excessive spatter in MIG/MAG welding.

Options:
• High inductance,
• low inductance,
• short CTWD,
• pulse current.

30. A fracture test is designed as a _ _ _ _ _ _ _ type of test.

Options:
• Qualitative,
• purnative,
• quantitative,
• subjective

31. A _ _ _ _ _ _ _ _ is designed for use on butt welds.

Options:
• Fracture test,
• nick break test,
• peel test,
• pull test

32. A nick break test is designed as a _ _ _ _ _ _ _ _ type of test.

Options:
• Purnative,
• qualitative,
• subjective,
• quantitative

33. A _ _ _ _ _ _ _ _ _ flaw is more likely to be found by a nick break test.

Options:
• Undercut,
• underfill,
• lack of fusion,
• crater crack

34. Using the radiographic NDT method and a double wall single image exposure, the film
goes outside and the source goes _ _ _ _ _ _ _ _ _.

Options:
• Inside,
• around the total circumference,
• outside,
• both sides
CSWIP 3.1 Homework : Leading Multiple Choice Questions
Paper 2

Name: ……………………………….…………………………. Date: ……………………

1 The maximum hardness in the HAZ of a steel will increase if:

a Heat input is increased.

b CEV is increased.
c Joint thickness is decreased.
d Basic electrodes are used.

1a. With reference to the previous question, what else can also cause this condition?

a. Low heat input

b. Slow travel speed
c. High pre heat temperatures
d. High amperages

2 Initiation of a TIG arc using a high frequency spark may not be allowed because it:

a Often causes tungsten inclusions.

a Can damage electronic equipment.
b Is an electrical safety hazard.
c Often causes stop/start porosity.

2a. With reference to the previous question, what does this function help with?

a. Cathodic cleaning
b. Penetration
c. Arc initiation
d. Crater filling

3 In friction welding, the metal at the interface when the joining occurs is described as
being in the:

a Liquid state.
b Intercritical state.
c Plastic state.
d Elastic state.

3a With reference to the previous question, what is the advantage of this welding
Process?

a. High deposition rate

b. Improved properties
c. Highly transportable
d. Bulk pack wire feed systems can be used
4 What four criteria are necessary to produce hydrogen induced cold cracking?

a Hydrogen, moisture, martensitic grain structure and heat.

b Hydrogen, poor weld profiles, temperatures above 200oC and a slow cooling rate.
c Hydrogen, a grain structure susceptible to cracking, stress and a temperature
below 300oC.
d Hydrogen, existing weld defects, stress and a grain structure susceptible to
cracking.

4a With reference to the previous question, why is temperature important in this

Cracking mechanism?

a. At low temperatures the hydrogen is less mobile

b. At high temperatures the hydrogen is less mobile
c. At low temperatures grain growth occurs
d. At high temperatures more hydrogen is absorbed

5 Austenitic stainless steels are more susceptible to distortion when compared to ferritic
steels this is because:

a High coefficient of thermal expansion, low thermal conductivity.

b High coefficient of thermal expansion, high thermal conductivity.
c Low coefficient of thermal expansion, high thermal conductivity.
d Low coefficient thermal expansion, low thermal conductivity.

5a With reference to the previous question and the correct answer, do these features
make it more susceptible to hydrogen cracking?

a. It depends on the welding process

b. It does not harden on cooling therefore, no.
c. It depends on the CEV value
d. Pre heating will be critical to avoid hydrogen cracking

6 All weld tensile test:

a Is used to measure the ultimate tensile strength.

b Is used to measure the elongation of the sample.
c Is used to measure the yield strength of a sample.
d All of the above.

6a With reference to the previous question, what is the UTS of a material?

a. The maximum load applied

b. The point of failure
c. The proof stress of the material
d. Where permanent deformation has occurred
7 In the welding of austenitic stainless steels, the consumables and plate materials are
often specified to be low carbon content. The reason for this:

a To prevent the formation of cracks in the HAZ.

b To prevent the formation of chromium carbides.
c To prevent cracking in the weld.
d Minimise distortion.

7a With reference to the previous question, what is this type of mechanism know as?

a. Creep
b. Weld decay
c. Solidification cracking
d. Crevice corrosion

8 Essential variable:

a In a WPS may change the properties of the weld.

b In a WPS may influence the visual acceptance.
c In a WPS may require re-approval of a weld procedure.
d All of the above.

8a With reference to the previous question and the correct answer, which of the
following is not an essential variable?

a. Heat input
b. Current type
c. Cleaning method
d. Mode of metal transfer

9 In an all weld metal tensile test, the original test specimens gauge length is 50mm.
After testing the gauge length increased to 72mm, what is the elongation percentage?

a 44%.
b 144%.
c 69.4%.
d 2.27%.

9a With reference to the previous question, what is exactly being measured here?

a. Ultimate tensile strength

b. Yield strength
c. Ductility
d. Toughness

10 Which of the following will vary the most when varying the arc length using the MMA
welding process?

a Voltage.
b Amperage.
c Polarity.
d Both a and b.
10a With reference to the previous question and the correct answer, what is the
electrical characteristic referred to as for this process?

a. Flat characteristic
b. Constant voltage
c. Constant current
d. Variable amperage

11 An undesirable property of aluminium oxide residue is that it:

a Creates problems when welding in position (vertical, horizontal, overhead).

b It melts at a higher point than the aluminium
c Forms a slag
d Decreases weld pool fluidity.

11a With reference to the previous question and the correct answer, how can this
issue be overcome using the TIG process?

a. Use alternating current

b. Use Direct current negative polarity
c. Use Direct current positive polarity
d. All options can be used for this purpose

12 A welder qualified in the PG position would normally be qualified for welding:

a All diameters of pipe.

b Welding positions PA, PC, PG, and PF.
c In position PG only.
d All pipe wall thickness.

12a With reference to the previous question and the correct answer, why would this be
the case?

a. With certain diameter of pipes all diameters are approved

b. The arc characteristics and technique are unique to this welding position
c. Pipe thickness are not covered with approval ranges
d. Certain welding positions are very similar

13 A fabrication calls for the toes to be blended in by grinding. The most likely reason for
this is to…

a Make the weld suitable for liquid (dye) penetrant inspection

b Improve the fatigue life
c Reduce residual stresses
d Improve the general appearance of the welds
13a With reference to the previous question and the correct answer, this will reduce?

a. Internal stresses
b. Stress raisers
c. Longitudinal stresses
d. Tensile stresses

14 A carbon equivalent of 0.48%:

a Is high for carbon steel and may require a preheat temperature over 100oC.
b Is insignificant for carbon steel and preheat will not be required.
c Is calculated from the heat-input formula.
d Is not a consideration for determining preheating temperatures.

14a With reference to the previous question, what could happen if pre heat was
required but was not carried out?

a. Possibility of martensite being formed

b. Possibility of hydrogen being formed
c. Possibility of solidification cracking
d. Possibility of lamellar tearing

15 Which of the following statements is true?

a The core wire of an MMA electrode has a lower melting point than the flux.
b Basic electrodes are preferred when welding is carried out in situations where
porosity free welds are specified.
c Rutile electrodes always contain a large proportion of iron powder.
d Cellulose electrodes may deposit in excess of 90ml of hydrogen per 100g of weld
metal.

15a With reference to the previous question and the correct answer, what’s unique
about these electrodes?

a. They are not hygroscopic

b. They have a high recovery rate
c. They have a stronger arc force
d. The core is made from a high grade steel
 Drag and drop

There could be more than one answer to the question

16. What precautions can be taken to avoid hydrogen cracking?

Options:
• Pre set joint,
• peen the weld after completion,
• ensure good fit up,
• avoid poor weld profiles,
• use a weave technique,
• ensure workshop temperature is above 20°c.

17. What level of hydrogen in ml is considered as a good precaution against HICC?

Options:
• 5ml,
• 8ml,
• 10ml,
• 12ml,
• 15ml,
• 20ml.

18. Which of the following welding processes would be less likely to produce HICC?

Options:
• SAW,
• MAG,
• MMA,
• FCAW,
• MIG,
• TIG.

19. What information would be required to determine the pre heat level?

Options:
• Joint type,
• shielding gas type,
• polarity used,
• CE value,
• welding position,
• welding process,
• heat input,
• electrode size.
20. Which of the following MMA electrode types would be most suitable to avoid the risk
of HICC?

Options:
• E6010,
• E7018,
• E6011,
• E8018,
• E6012,
• E6013.

21. Which of the following could be used to prevent solidification cracking?

Options:
• Use a low dilution welding process,
• Pre heat,
• add manganese to filler material,
• PWHT,
• use a low hydrogen process,
• depth to width ratio above 2:1.

22. Which of the following are not solidification cracking preventative measures?

Options:
• Minimise stress,
• pre set joint,
• use low sulphur content material,
• use stringer beads,
• use a short arc length,
• clean joint of contaminants.

23. Which of the following is not something used to avoid Lamellar tearing.

Options:
• Avoid restraint,
• use a forged tee section,
• use a temper bead technique,
• butter weld faces,
• change joint design,
• minimise stress and restraint.
24. Lamellar tearing is more likely in which of the following?

Options:
• 5mm thick tee joint,
• 10mm thick double vee butt joint,
• 10mm double U butt,
• 50mm thick tee butt joint,
• 60mm thick double vee butt joint,
• 100mm thick tee butt joint.

25. Which of the following is not connected with weld decay?

Options:
• Chromium carbide,
• sensitisation,
• iron sulphides,
• stabilised,
• manganese sulphide,
• iron carbide,
• chevron,
• inter granular corrosion.

26. For a stainless steel to be classed as low carbon, what percentage carbon does it
have to be below?

Options:
• 0.1%,
• 0.09%,
• 0.04%,
• 0.05%,
• 0.08%,
• 0.07%,
• 0.06%.
 Fill the blank

Add the missing word from the options given

27. Using the radiographic NDT method of inspection using the double wall double image
exposure, both the film and source goes _ _ _ _ _ _ _ _.

Options:
• Inside,
• outside,
• both sides,
• all around

28. A welder qualification certificate _ _ _ _ _ _ _ record the tests conducted on the

specimen.

Options:
• Does not,
• does,
• occasionally,
• in certain circumstances

29. Carbon arc gouging can cut _ _ _ _ _ _ _ _ _.

Options:
• only stainless steel and aluminium,
• only carbon steel and stainless steel,
• only non-ferrous materials,
• ferrous and non-ferrous materials

30. On a CMn steel butt weld _ __ _ _ _ _ _ will require a decrease in pre heat
temperature.

Options:
• increasing weld speed,
• increasing gas flow rate,
• increasing heat input,
• decreasing heat input
31. On a CMn steel butt weld, changing from a stringer to a weave technique will
require_ _ _ _ _.

Options:
• More pre heat,
• less pre heat,
• more amperage,
• a change in polarity

32. Changing the joint configuration from a tee fillet to a butt joint will require _ _ _ _ _.

Options:
• More pre heat,
• a change in polarity,
• less pre heat,
• an increase in welding speed

33. To prevent solidification cracking _ _ _ _ _ _ _ _ form between the grains to maintain

cohesion.

Options:
• Iron sulphides,
• manganese sulphides,
• magnesium sulphides,
• aluminium sulphides

34. To measure a materials susceptibility to Lamellar tearing, _ _ _ _ _ _ _ _ _ is

measure after a STRA test.

Options:
• UTS,
• yield,
• reduction in area,
• proof stress

35. In a stabilised stainless steel, the element _ _ _ _ _ _ _ _ _ helps prevent chromium

carbides forming which leads to weld decay.

Options:
• Chromium,
• carbon,
• titanium,
• nickel
36. Pre heat on a CMn steel repair would normally need to be _ _ _ _ _ _ _.

Options:
• higher than the original weld,
• lower than the original weld,
• not required,
• the same as the original weld
CSWIP 3.1 Homework: Leading Multiple Choice Questions
Paper 3

Name: ……………………………….…………………………. Date: ……………………

1. A typical temperature range for baking basic coated electrodes is?

a. 150 - 200°C
b. 200 - 250°C
c. 300 - 350°C
d. 400 - 450°C

1a With reference to the previous question, why does this have to be done?

a. These electrodes are hygroscopic

b. It allows equalization of the alloying elements
c. It helps bonds the core to the flux
d. It stop the flux from flaking off

2. If welding travel speed is doubled but the current and voltage remain the same, the heat
input will be?

a. Reduced by 50%
b. Increased by a factor of two
c. About the same
d. Reduced by approximately 25%

2a. With reference to the previous question, what could be the possible outcome of this?

a. Increased hardness
b. Increased toughness
c. Improved weldability
d. The material would be sensitised

3. What type of submerged arc welding flux would be susceptible to moisture pickup?

a. Neutral
b. Agglomerated
c. Fused
d. All about the same

3a. With reference to the previous question, why is this the case?

a. It’s because they are very dry

b. It’s because they are hygroscopic
c. It’s because they are droscopic
d. It’s because they are endoscopic
4. A large grain size in the HAZ of a CMn steel weld joint may have?

a. Low ductility
b. Low toughness
c. High toughness
d. High tensile strength

4a. With reference to the previous question and the correct answer, what would have caused
this condition?

a. Welding in the horizontal position

b. Too high a pre heat
c. Multi pass welding
d. Welding speed too slow

5. The property of a material which has the greatest influence on welding distortion is it’s?

a. Yield strength
b. Material thickness
c. Elastic modulus
d. Coefficient of thermal conductivity

5a. With reference to the previous question and the correct answer, why is this the case?

a. Thick materials rarely distort

b. The more elastic they are the more they distort
c. Low yield materials will distort more
d. High yield materials will distort more

6. Which of the following is associated with SAW more often than it is with MMA welds?

a. Hydrogen cracking in the weld metal

b. Solidification cracking in the weld metal
c. Reheat cracking during PWHT
d. Lamellar tearing

6a. With reference to the previous question and the correct answer, why is this the case?

a. Low dilution process

b. High dilution process
c. Contaminated flux
d. Low heat input process
7. EN ISO 5817 (Level C) specifies that the limit for the diameter (D) of a single pore in a
weld is?

D equal to or less than 0.3s, but maximum 4mm where s = material thickness.
For which of the following situations is the pore acceptable?

a. S = 20mm, measured pore diameter = 5mm

b. S = 15mm, measured pore diameter = 4.5mm
c. S = 10mm, measured pore diameter = 3mm
d. S = 10mm, measured pore diameter = 3.5mm

7a. With reference to the previous question, what could be the possible cause of these pores?

a. MAG welding C Mn steel with a gas flow rate of 18 litres per minute, voltage 29,
amperage 160 in the vertical up position.
b. MAG welding C Mn steel with a gas flow rate of 18 litres per minute, voltage 20,
amperage 120 in the vertical up position.
c. MAG welding C Mn steel with a gas flow rate of 15 litres per minute, voltage 18,
amperage 100 in the vertical up position.
d. MAG welding C Mn steel with a gas flow rate of 15 litres per minute, voltage 16,
amperage 90 in the vertical up position.

8. Typical temperatures used for normalising a C Mn steel plate are?

a. 600 - 650°c
b. 1000 - 1100°c
c. 700 - 800°c
d. 880 - 920°c

8a. With reference to the previous question, what actually does normalising do?

a. Softens the material making it easier to from

b. Hardens the material, ideal for certain applications
c. Produces a fine grain structure
d. Produces a coarse grain structure

9. For GMAW the burn off rate of the wire is directly related to?

a. Sick out length

b. Wire feed speed
c. Arc voltage
d. Travel speed

9a With reference to the previous question, how is this parameter measured?

a. Volts
b. Inductance
c. Amps
d. Resistance
10. If arc strikes are found on carbon steel (carbon equivalent of 0.5%), what undesirable
grain structure may be present?

a. Pearlite.
b. Martensite.
c. Ferrite.
d. All of the above are undesirable grain structures in constructional steels.

10a. With reference to the previous question, what features does this grain structure have?

a. A very soft and ductile structure.

b. Hard and unstable structure
c. Good impact properties but poor tensile properties
d. Good tensile properties because of its ductility

11. Which of the following units is used to measure the energy absorbed in charpy impact
testing.

a. Newtons
b. Pascals
c. Joules
d. Mega Pascals

11a. With reference to the previous question, what does this test tell us?

a. Its toughness at a given temperature

b. Its yield and UTS values
c. Its proof stress value
d. Its resistance to cyclic loading

12. What does the 70 represent on an E7018 AWS A5.1 classified electrode?

a. 70 N/mm2 minimum UTS.

b. 70N/mm2 minimum impact strength.
c. 70,000 p.s.i. minimum UTS.
d. 70,000 p.s.i. minimum yield strength.

12a. With reference to the previous question, what type of flux coating does this electrode
have?

a. Basic
b. Rutile
c. Cellulosic
d. Iron powder
13. Which of the following tests would you not expect to be carried out on a welder
qualification test?

a. Radiography.
b. Tensile test.
c. Macro.
d. Bend test.

13a. With reference to the previous question, which of the tests is considered a quantitative
test?

a. Bend test
b. Macro
c. Radiography
d. Tensile test

14. Which material would be the least effective for DPI?

a. 316 L stainless steel

b. Carbon manganese steel
c. Cast Iron.
d. Both a and c.

14a. with reference to the previous question, the main reason why this would be the case is
that the material is?

a. Non magnetic
b. Porous
c. Carbon content too high
d. Thermal conductivity too low

15. Globular transfer is used in which welding process?

a. TIG
b. MMA/SMAW
c. GMAW/MAG
d. SAW

15a. With reference to the previous question and the correct answer, what current is used
for this type of transfer mode?

a. AC
b. DC and AC
c. DC-
d. DC+
 Drag and drop

There can be more than one answer to each question

16. Restraint can help prevent distortion but what else does it increase?

Options:
• Porosity,
• heat input,
• residual stress,
• fatigue,
• bending,
• yield strength.

17. Which of the following properties has an effect on distortion?

Options:
• Thermal conductivity,
• yield value,
• elongation,
• impact value,
• coefficient of thermal expansion,
• relative density.

18. What is the correct temperature for annealing?

Options:
• 200°c,
• 500°c,
• 650°c,
• 700°c,
• 750°c,
• 800°c,
• 850°c,
• 720°c,
• 920°c
19. What is the correct temperature range for PWHT?

Options:
• 250°c - 300°c,
• 350°c - 450°c,
• 400°c - 500°c,
• 550°c - 650°c,
• 750°c - 850°c,
• 900°c - 950°c.

20. Electrodes classified to AWS 5.1 display the following in their designation?

Options:
• Yield strength,
• Rm value,
• welding position,
• charpy impact value,
• CTOD value,
• proof stress,
• flux type.

21. Basic electrodes, unless they are in a vacuum pack, require baking and then kept
warm before use, which of the following are the correct temperatures for this?

Options:
• 350°c,
• 200°c,
• 100°c,
• 150°c,
• 75°c,
• 50°c

22. Some of the advantages of TIG welding are?

Options:
• High deposition rate compared to MIG/MAG,
• low hydrogen levels produced,
• no spatter,
• easy slag removal,
• high operational percentage,
• high toleration of contaminants.
23. Some of the disadvantages of TIG welding are?

Options:
• Low deposition rates,
• slag inclusions,
• not all positional,
• low toleration to contaminants,
• high skill required,
• lack of fusion in Dip.

24. Which of the following are constant during the MIG/MAG process?

Options:
• Voltage,
• gas flow rate,
• CTWD,
• wire feed speed,
• travel speed.

25. In MIG/MAG pulse welding, which of the following adjustments would increase heating
on the surface of the weld.

Options:
• increase pulse height,
• increase background time,
• decrease background height,
• decrease pulse height,
• increase background height.
 Fill the blank

Add the missing word from the options given

26. Welding around the _ _ _ _ _ _ _ will reduce the level of distortion.

Options:
• The ends,
• the flange,
• end axis,
• neutral axis

27. Annealing is done to _ _ _ _ _ _ the material.

Options:
• Soften,
• harden,
• improve tensile strength,
• improve toughness

28. Pre heat measurement on materials above 50mm thick are done _ _ _ _ _ _ _ from the
bevel face.

Options:
• 25mm,
• 30mm,
• 55mm,
• 75mm

29. The electrode designation E8018 to AWS 5.1 would mean the electrode is a
_ _ _ _ _ _ type.

Options:
• Rutile iron powder,
• basic,
• cellulosic,
• rutile
30. In MMA welding, cellulosic electrodes are designed to be used in this welding position _
_ _ _ _ _ _ _ also known as stoving.

Options:
• PG,
• PF,
• PC,
• PD

31. A _ _ _ _ _ _ _ _ _ is deployed with the Tig welding process to prevent crater cracking.

Options:
• Pre gas supply,
• slope out current,
• post gas supply,
• slope in current

32. When welding CMn steel with the Tig welding process, the tungsten electrode should
have a _ _ _ _ _ __ _ preparation.

Options:
• Long taper with a point,
• short taper with no point,
• short taper rounded at the end,
• no preparation

33. Positional welding can be done in spray transfer when using _ _ _ _ _ _ _ _ _.

Options:
• Solid wires,
• C0₂,
• flux cored wires,
• mixed gases
34. Flux cored wires have a higher deposition rate because _ _ _ _ _ _ _ _ _.

Options:
• of the flux,
• of higher resistance,
• of lower resistance,
• of no resistance

35. In the submerged arc welding process, if _ _ _ _ _ _ _ is increased penetration

will decrease.

Options:
• Wire feed,
• inductance,
• voltage,
• gas flow