SECTION 12.

QUESTIONARY

Q1. In TIG welding the best welding results are

usually obtained with:
a. DC electrode negative
b. DC electrode positive
c. AC
d. a and b above
 SECTION 12. QUESTIONARY

Q2. In TIG welding diameter of electrode.

a. Is larger in AC compared to DC -ve.

b. Is same for AC DC.
c. Should be according to Voltage use.
d. Is larger in DC +ve compared to AC
 SECTION 12. QUESTIONARY

Q3. The current carrying capacity of a DC positive

electrode is about.

a. Half of that used in AC

b. One tenth that of a DC –ve
c. Half of a DC –ve
d. Is Equal to AC.
 SECTION 12. QUESTIONARY

Q4. In TIG welding DCEN polarity,weld profile is.

a. Medium,wide
b. Deep, narrow
c. Shallow, wide
d. Narrow,shallow.
 SECTION 12. QUESTIONARY

Q5. Which of the following statement is not true for

TIG welding.
a. Travel speed affects both weld width and penetration but
the effect on width is more pronounced.
b. Increasing the travel speed reduces the penetration and
width
c. Reducing the travel speed increases the penetration and
width
d. Increasing the travel speed increases the penetration and
width
 SECTION 12. QUESTIONARY

Q6. Which type of TIG welding electrode have

higher current carrying capacity than pure
tungsten electrodes and maintain a sharp tip
for longer.
 
a. Ceriated and lanthaniated electrodes
b. Zirconiated electrodes
c. Pure tungsten electrodes
d. None of the above.
 SECTION 12. QUESTIONARY

Q7. If the vertex angle of TIG electrode is

increased.

a. The penetration increases.

b. Bead width increases.
c. It melts the tip of the electrode causing tungsten inclusion.
d. a and b above
 SECTION 12. QUESTIONARY

Q8. The following inert gases cannot be used as

shielding gases for TIG welding:
 
a. Mixtures of argon and helium
b. Argon
c. Nitrogen
d. Helium
 SECTION 12. QUESTIONARY

Q9. What will be the effect if Gas flow rate is too

low in TIG welding.
 
a. Turbulence occurs at the base of the shielding gas column.
b. Suck back will occur at the root run.
c. It causes the tip of tungsten electrode to overheat.
d. Though Inert, the shielding gas cannot remove the air from
the weld area and this may result in porosity and
contamination.
 
 SECTION 12. QUESTIONARY

Q10. The basic reason to use Purge gas in TIG

welding is to.

a. exclude all the contaminants at the back of the weld

b. Protect the back of the weld from excessive oxidation.
c. Produce smooth root run in Pipe.
d. To keep the weld metal from excessive heat.
 
 
 SECTION 12. QUESTIONARY

Q11. In TIG welding Electrode extension.

 

a. Is recessed inside the gas nozzle

b. Is the distance from the nozzle face to the tungsten tip
c. Is the distance from the contact tube to the tungsten tip
d. Should be 2 to 3 times the electrode
 
 SECTION 12. QUESTIONARY

Q12. Which of the following statement is true for TIG

welding.
 
a. Small additions of elements in filler wire ,that have similar
composition to parent metal , will combine with any
oxygen and nitrogen present.
b. TIG welding can be cannot be conducted without filler
wire.
c. Filler wire can also be used as an electrode.
d. Tungsten electrode does not get consumed used for TIG
welding.
 
 SECTION 12. QUESTIONARY

Q13. Cause of tungsten inclusion in TIG welding is

due to.
 
a. Larger diameter of electrode
b. Larger vertex angle of electrode.
c. Welding current too low
d. Thermal shock to electrode.
 

 
 SECTION 12. QUESTIONARY

Q14. Crater cracking In TIG welding can be

avoided by.
 
a. Using Thoriated electrode
b. Using flat characteristics for Amp- voltage
c. Using power source with drooping current
d. Using power sources that have a current slope-out device.
 
 
 SECTION 12. QUESTIONARY

Q15. Which statement is not true regarding

disadvantages of TIG welding.
 
a. Need for higher dexterity and welder co-ordination than
with MIG/MAG or MMA welding.
b. The process does not have any cleaning action and so has
low tolerance for contaminants on filler or base metals.
c. The heat source and filler metal additions are controlled
independently and thus it is very good for joining thin base
metals.
d. Gives low deposition rates compared with other arc
welding processes
 
 SECTION 13. QUESTIONARY

Q1. In MIG/MAG process what is not correct.

 
a. In semi-automatic welding, the wire feed rate and arc
length are controlled automatically.
b. In Mechanised welding, all parameters are under automatic
control, but they can be varied manually during welding.
c. Power house with constant drooping current is used.
d. The MIG/MAG process uses semi-automatic, mechanised
or automatic equipment
 
 SECTION 13. QUESTIONARY

Q2. The MIG/MAG process offers high productivity

because.
 
a. The consumable wire is continuously fed.
b. The consumable wire is capable of offering high speed
welding.
c. After weld cleaning is not required.
d. The constant voltage power source helps in high travel
speed.
 
 SECTION 13. QUESTIONARY

Q3. In MIG/MAG welding Increasing the wire feed

speed
 
a. Automatically increases the current in the wire.
b. Cause Increase of both wire feed speed current and voltage
and will increase heat input.
c. will cause the voltage to drop in the circuit
d. controls the arc length
 
 SECTION 13. QUESTIONARY

Q4. An increase of both wire feed speed/current

and voltage.
 
a. Voltage does not increase but will remain constant in
MIG/MAG welding
b. Increase heat input
c. Decrease production
d. Will cause arc deflection

 
 SECTION 13. QUESTIONARY

Q5. For non-ferrous metals and their alloys (such as

Al, Ni and Cu) an inert shielding gas to be
used is.
 
a. pure argon
b. 99.9% Argon
c. Argon with 2% nitrogen
d. None of the above.
 

 
 SECTION 13. QUESTIONARY

Q6. Both argon and CO2 gas in mixtures of

between 5-20%CO2 benefits in.
 
a. Good penetration with a stable arc and little spatter.
b. Use of low current thereby reducing heat input.
c. Giving the stable arc
d. Aids in increasing the travel speed thereby increasing
weld production 

 
 SECTION 13. QUESTIONARY

Q7. Argon +1 to 5%CO2 are widely used in

welding of.
 
a. stainless steels and some low alloy steels.
b. Non ferrous metals.
c. Nickel and its alloys
d. Aluminium and its alloys

 
 SECTION 13. QUESTIONARY

Q8. Some Ar-He mixtures containing up to 2.5%N2

are available for welding
 
a. Austenitic Stainless steel
b. Ferritic stainless steel
c. Martensitic stainless steel
d. None of the above

 
 SECTION 13. QUESTIONARY

Q9. In MIG/MAG welding Argon can be used for

aluminium
 
a. Because Argon is best inert gas available
b. Because there is sufficient surface oxide available to
stabilize the arc.
c. Because Argon aids in good thermal conductivity.
d. None of the above statement is correct.

 
 SECTION 13. QUESTIONARY

Q10. In MIG/MAG welding the faster the travel

speed.
 
a. The less penetration
b. narrower bead width
c. higher risk of undercut
d. All the above statements are true.
 

 
 SECTION 13. QUESTIONARY

Q11. The CTWD has an influence over.

 
a. The welding current
b. The welding Voltage
c. Parent metal
d. Filler wire used.
 
 SECTION 13. QUESTIONARY

Q12. In MIG/MAG welding the burn-off rate

increases

a. As the voltage increases

b. As the electrode extension is increased
c. The porosity in weld metal
d. Due to increased travel speed.
 
 SECTION 13. QUESTIONARY

Q13. For spray metal transfer mode CTWD should

be.
 
a. 10-15
b. 20-25
c. 15-20
d. CTWD is independent of Metal transfer mode
 
 
 SECTION 13. QUESTIONARY

Q14. Nozzle to work distance has a considerable

effect on
 
a. laminar gas flow to protect the weld pool from
atmospheric contamination
b. gas shielding efficiency
c. Metal transfer mode
d. Weld metal cooling
 
 
 
 SECTION 13. QUESTIONARY

Q15. Spray transfer occurs at

 
a. high currents and voltages
b. High voltage and low current
c. High current and low voltage
d. None of the above.
 
 
 SECTION 13. QUESTIONARY

Q16. Inductance is the property in an electrical

circuit that
 
a. slows down the rate of current rise
b. slows down the rate of Voltage rise
c. Speeds up the Voltage rise
d. a and c above
 
 
 SECTION 13. QUESTIONARY

Q17. In FCAW Most wires

 
a. Are sealed mechanically with various forms of
joint.
b. Are sealed hermetically with various forms of
joint.
c. Are sealed automatically with various forms of
joint.
d. Both a and b above.

 
 SECTION 13. QUESTIONARY

Q18. In FCAW use of Rutile wire.

 
a. Gives excellent root run capabilities
b. Does not require external gas at all
c. Is good on ‘dirty’ material
d. Give good positional capabilities
 
 SECTION 13. QUESTIONARY

Q19. Typical welding imperfection that occur in

MIG/MAG are.
 
a. Silica inclusions (on ferritic steels only) caused by poor
inter-run cleaning
b. Lack of sidewall fusion during Spray transfer welding
thick section vertically down
c. Burn through from using the incorrect metal transfer mode
on thick metal.
d. All of the above.
 
 SECTION 13. QUESTIONARY

Q20. In MIG/MAG welding Teflon liners are used.

 
a. For steel wires
b. For copper wire
c. To minimize wire feed problem
d. None of the above.

 
 SECTION 14. QUESTIONARY

Q1. What are the restrictions for the use of

powdered flux in SAW.
 
a. The use of powdered flux restricts the process to the flat
and horizontal-vertical welding positions.
b. The use of powdered flux restricts the process to the
overhead welding positions.
c. The use of powdered flux restricts to use of constant
voltage in SAW.
d. The use of powdered flux Causes the exposure of UV and
infrared radiation.
 
 
 SECTION 14. QUESTIONARY

Q2. In SAW the current/polarity used is.

 
a. AC is often preferred to avoid the problem of arc blow
b. DC electrode positive polarity is employed up to about
1000A
c. DC electrode negative is needed to reduce penetration and
dilution.
d. All of the above
 
 
 SECTION 14. QUESTIONARY

Q3. Submerged arc welding is widely used in the

fabrication of.
 
a. Ships.
b. Short weld length welds.
c. Overhead welds
d. Below 1,5 mm. welds.
 
 SECTION 14. QUESTIONARY

Q4. In SAW Flux may be defined as

 
a. Granular organic compounds mixed to various
formulations.
b. Granular mineral compounds mixed to various
formulations.
c. Heated organic compounds mixed to various formulations.
d. Powdered organic compounds mixed to various
formulations.
 
 SECTION 14. QUESTIONARY

Q5. Fluxes that are produced where particles are

crushed and screened to yield a uniform glass-
like product.
 
a. Are called Fused Fluxes
b. Are called agglomerated fluxes
c. Are specially used for horizontal welding.
d. b and c above
 SECTION 14. QUESTIONARY

Q6. Agglomerated fluxes are generally

 
a. Have good chemical homogeneity.
b. Less hygroscopic, thus handling and storage are easier.
c. Can be identified by colour coding.
d. None of the above.
 SECTION 14. QUESTIONARY

Q7. In SAW Advantages of fused fluxes are.

 
a. Deoxidisers and alloying elements can easily be added to
the flux to adjust the weld metal composition.
b. Allow a thicker flux layer when welding.
c. Are generally more hygroscopic (re-baking hardly
practical).
d. None of the above
 
 SECTION 14. QUESTIONARY

Q8. Regarding welding current in SAW Which

statement is not correct.
 
a. Increasing current decreases penetration and wire melt-off
rate
b. Excessively high current produces a deep penetrating arc
with a tendency to burn-through, undercut or a high,
narrow bead prone to solidification cracking.
c. Excessively high current produces an unstable arc, lack of
penetration and possibly a lack of fusion.
d. a and c are incorrect.
 SECTION 14. QUESTIONARY

Q9. In SAW Increasing the arc voltage with

constant current and travel speed will:
 
a. Help to bridge excessive root opening when fit-up is poor
b. Increase flux consumption
c. Tend to reduce porosity caused by rust or scale on steel
d. All of the above
 
 SECTION 14. QUESTIONARY

Q10. In SAW reducing the arc voltage with constant

current and travel speed will:
 
a. Produce a wide bead shape that is subject to solidification
cracking
b. Make slag removal difficult in groove welds
c. Produce a stiffer arc which improves penetration in a deep
weld groove and resists arc blow
d. Over alloy the weld metal, via the flux
 
 SECTION 14. QUESTIONARY

Q11. If the travel speed is increased in SAW.

 
a. Heat input per unit length of weld is decreased
b. More filler metal is applied per unit length of weld and
consequently less excess weld metal
c. Penetration Increases and thus the weld bead becomes
smaller
d. Cause difficult slag removal along the weld toes

 
 SECTION 14. QUESTIONARY

Q12. At any given amperage setting, a small

diameter electrode.
 
a. Will have a higher current density and deposition rate of
molten metal than a larger diameter electrode.
b. Carry more current than a larger one.
c. produce a higher deposition rate at higher amperage
d. Penetration decreases and thus the weld bead become
larger
 
 SECTION 14. QUESTIONARY

Q13. What is correct regarding the electrode

extension in SAW
 
a. It is the distance the continuous electrode protrudes
beyond the contact tip.
b. At lower current densities, resistance heating of the
electrode between the contact tip and the arc can be
utilised to increase the electrode melting rate
c. The lower the extension, the greater the amount of heating
and the higher the melting rate
d. All the above statements are correct.
 
 SECTION 14. QUESTIONARY

Q14. The width and depth of the layer of granular

flux in SAW.
 
a. Will influence the appearance and soundness of the
finished weld as well as the welding action.
b. The melting rate of a stainless steel electrode will be
higher than that of a carbon steel electrode.
c. Larger diameter electrode can carry more current than a
smaller one.
d. Electrode can ultimately produce a higher deposition rate
at higher amperage.
 
 
 SECTION 14. QUESTIONARY

Q15. Copper-coated electrodes provide.

 
a. Contamination by carbon containing materials such as oil,
grease, paint
b. Result in hydrogen being absorbed in the weld pool.
c. Causes Carbon pick-up in the weld metal
d. Assurety of good electrical contacts and helps in smooth
feeding.
 
 
 SECTION 14. QUESTIONARY

Q16. Usually in SAW.

 
a. A constant voltage (or flat) characteristic power source is
used.
b. A flat characteristic power source is used.
c. A constant amperage (or flat) characteristic power source
is used.
d. a and b is correct
 

 
 SECTION 15. QUESTIONARY

Q1. The oxy-fuel cutting process cuts or removes

metal
 
a. By the chemical reaction of oxygen with the nitrogen at
elevated temperatures.
b. By the chemical reaction of oxygen with the metal at upper
transformation temperatures.
c. The oxy-fuel cutting process cuts or removes metal by the
heating reaction of oxygen with the metal at elevated
temperatures.
d. By the chemical reaction of oxygen with the metal at
elevated temperatures.
 
 SECTION 15. QUESTIONARY

Q2. In oxy-fuel cutting Metal oxides, together with

molten metal, are expelled from the cut by
 
a. Kinetic energy of the oxygen stream.
b. Moving the torch across the workpiece
c. Gravitational force
d. None of the above.
 
 
 
 SECTION 15. QUESTIONARY

Q3. In order to be cut by the oxy-fuel cutting

process, a material must simultaneously fulfil
two conditions:
 
a. Burning temperature must be below the parent material
melting point.
b. Burning temperature must be below the parent material
melting point.
c. Melting temperature of the oxides formed during the
cutting process must be above the parent material melting
point.
d. b and c above
 SECTION 15. QUESTIONARY

Q4. Advantages of oxy-fuel cutting are.

 
a. Basic equipment costs are low compared to machine tools.
b. Economical method of plate edge preparation.
c. Large plates can be cut rapidly in place by moving the
torch rather than the plate.
d. All the above statements are true
 
 
 
 SECTION 15. QUESTIONARY

Q5. Oxygen used for cutting operations should

have a purity of.
 
a. 95%
b. 99.5% or higher
c. 99.5% or lower
d. Above 95 %
 
 
 
 SECTION 15. QUESTIONARY

Q6. Lower purity of Oxygen will result in

 
a. An increasing in cutting speed and an
b. Increase in consumption of cutting oxygen
c. Reducing the efficiency of the operation.
d. b and c above

 
 
 SECTION 15. QUESTIONARY

Q7. In gas cutting Factors to be considered when

selecting a fuel gas include:
 
a. Time required for preheating when starting cuts.
b. Safety in transporting and handling.
c. Density of oxygen required per volume of fuel gas to
obtain a neutral flame.
d. a and b above

 
 SECTION 15. QUESTIONARY

Q8. Some of the more common fuel gases used

for Metal cutting are
 
a. natural gas (Octane)
b. Methyl acetylene propadiene
c. Liquid petroleum gas
d. Bio Gas.
 SECTION 15. QUESTIONARY

Q9. Main characteristics of propane are.

 
a. Low temperature flame, high heat content
b. Medium temperature flame
c. Rapid preheating and piercing
d. Highly focused, high temperature flame

 
 SECTION 15. QUESTIONARY

Q10. Generally, oxy-fuel cuts are characterised by:

 
a. Large kerf (<2mm)
b. Medium roughness values (Ra <50μm)
c. Poor edge angles (>0.7mm)
d. All of the above.
 SECTION 15. QUESTIONARY

Q11. Plasma arc cutting is an arc cutting process.

 
a. Where pilot arc is struck between a tungsten electrode and
a water-cooled nozzle.
b. That uses a constricted arc,which removes the molten
metal with a high velocity water jet of ionised gas issuing
from the constricting orifice.
c. Uses acetelen gas for cutting
a and b above are correct
 SECTION 15. QUESTIONARY

Q12. Advantages of plasma arc cutting are.

 
a. Operates at a much higher energy level compared to oxy-
fuel cutting resulting in faster cutting speed
b. Instant start-up is particularly advantageous for interrupted
cutting; this also allows cutting without preheat
c. Can be widely used for cutting all types of stainless steels.
d. All of the above.
 SECTION 15. QUESTIONARY

Q13. In metal cutting process where metal to be

gouged or cut is melted with an electric arc
and blown away with a high velocity jet of
compressed air is called.
 
a. Plasma arc cutting
b. Arc Air Gouging
c. Oxy fuel cutting
d. Oxy acetylene cutting
 
 SECTION 15. QUESTIONARY

Q14. Manual Metal arc gouging can be used.

 
a. For heavy gouging operation.
b. For removing weld defects
c. For preparing ‘U’ and ‘J’ preparations.
d. All of the above
 SECTION 15. QUESTIONARY

Q15. Advantages of arc air gouging

 
a. Fast – it is approximately 6 times faster than chipping.
b. Cannot be automated.
c. Easy to operate – the equipment is similar to MMA
equipment except the torch and air supply hose.
d. All of the above.
 SECTION 21. QUESTIONARY

Q1. The responsibility for safety in workshop or at

the site is of.
 
a. Welding Inspectors
b. Work shop/site in-charge
c. Safety Officer
d. All of the above
 
 SECTION 21. QUESTIONARY

Q2. One of the aspects of arc welding safety is.

 
a. Noise.
b. Type of welding machine, considering its voltage.
c. Safety norm set in contractual documents
d. None of the above
 
 SECTION 21. QUESTIONARY

Q3. The electric shock hazard associated with arc

welding is.
 
a. Primary voltage shock – 60 to 100V
b. Secondary voltage shock – 230 to 460V
c. Only a above
d. None of the above.
 
 SECTION 21. QUESTIONARY

Q4. Electric shock from the primary (input) voltage

can occur by touching
 
a. Electric mans
b. Main electric towers
c. Damaged Electric Panels
d. None of the above
 
 SECTION 21. QUESTIONARY

Q5. Secondary voltage shock occurs when

touching
 
a. damaged area on the electrode cable connecting the
terminals
b. by touching a lead inside the welding equipment with the
power to the welder switched on
c. Residual circuits
d. Main voltage circuit on Panels
 
 SECTION 21. QUESTIONARY

Q6. A correctly wired welding circuit should

contain three leads:
 
a. Welding lead, Mains lead , welding return lead
b. Welding return lead, Earth lead ,Mains lead
c. Welding lead , welding return lead, Earth lead
d. Welding lead, welding return lead, Voltage lead for
Welding machine  
 SECTION 21. QUESTIONARY

Q7. To establish whether the capacity of any

piece of current carrying equipment is
adequate for the job, the Visual/ Welding
Inspector can refer to.
 
a. Duty cycle
b. Rated output of welding machine.
c. low voltage safety devices
d. None of the above.
 SECTION 21. QUESTIONARY

Q8. Failure to carefully observe the duty cycle of

equipment can.
 
a. Over-stress the part.
b. Overheating welding leads.
c. Burning of welding machine
d. A and b above.
 SECTION 21. QUESTIONARY

Q9. Welding sparks can cause

 
a. Over stress on welding machine.
b. Ignite and cause fires to flammable materials near the
welding area to.
c. Serious burns.
d. Only b and c above
 SECTION 21. QUESTIONARY

Q10. Light radiation is emitted by the welding arc in

three principal ranges, in wave lengths:
 
a. Infra red (heat), Visible light, Ultra violet radiation
b. Infra red (heat), ionizing light, Ultra violet radiation
c. Radioactive light, Visible light, Ultra violet radiation
d. Infra red (heat), Visible light, white light
 
 SECTION 21. QUESTIONARY

Q11. Arc eye is caused by

 
a. Ionizing rays
b. UV rays
c. White light rays
d. a and b above.
 SECTION 21. QUESTIONARY

Q12. Visible light.

 
a. Damage the network of optically sensitive nerves on the
retina.
b. Reddening and irritation to the eyes.
c. Causes a gradual but irreversible opacity of the eye lens.
d. Blisters may form
 SECTION 21. QUESTIONARY

Q13. Fumes and gases from welding can cause.

 
a. Nausea and fever.
b. Dizziness.
c. Burning of eyes and skin.
d. All of the above.
 SECTION 21. QUESTIONARY

Q14. Some degreasing compounds that

decompose from the heat and UV radiation to
produce toxic gases are.
 
a. Trichloroethylene
b. Perchlorethylene
c. Oxyacetylene
d. a and b above.
 
 SECTION 21. QUESTIONARY

Q15. What is not true regarding noise.

 
a. Exposure to loud noise can permanently damage hearing.
b. If the noise exposure is greater than 85 decibels averaged
over an 8 hour period then hearing protection must not be
worn
c. The noise associated with welding is usually due to
ancillary operations such as chipping, grinding and
hammering.
d. All of the above.