1. The Discontinuity which results from the entrapment of gas within the weld cross-section is known
as:
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
Undercut
Lack of penetration
Lack of fusion
Porosity
2. A discontinuity can be called as a defect only when;
It is a Linear indication
It is a rounded indication
It exceeds the code limit
if it is a crack
3. Due to the improper termination of the welding arc which discontinuity is likely to be occurred;
Undercut
Incomplete penetration
Overlap
Crater crack
4. Dye-Penetrant test is carried out to detect;
Surface Discontinuity
Surface as well as subsurface discontinuity
Both a and b
Neither a nor b
5. In SMAW, E7018 belongs to which F group;
F4
F2
F1
F8
6. In SMAW, which one of the following electrodes doesn’t belong to the F2 group;
E 6010
E 6012
E 6013
E6014
7. Who is responsible for the qualification of welding procedures?
contractor or manufacturer
welding Engineer
welding operator
Third-party Inspection agency
8. Stray arc strikes are undesirable since they:
Leave a poor surface finish
Cause weld metal cracking.
Reduce corrosion resistance.
Cause local hardening and cracking in the parent material.
9. Welded joint in which the weld metal and parent metal have the same mechanical property and
chemical composition is called;
1.
1. Heterogeneous Joint
2. Dissimilar Joint
3. Homogeneous Joint
4. Transition joint Joint
10. Oxy pressure and nozzle size in flame cutting would influence;
1.
1. The temperature required for cut initiation
2. The ability to cut stainless steels
3. The depth of the cut obtained
4. None of the above
11. A code of practice is;
1.
1. A standard for workmanship only
2. A set of rules for manufacturing a specific product
3. Levels of acceptability of a weldment
4. None of the above
12. Movement of the arc in MMA welding by magnetic forces is called;
1.
1. Arc deviation
2. Arc misalignment
3. Arc blow
4. Arc eye
13. A metallurgical problem most associated with submerged arc welding is;
1.
1. Hydrogen cracking in the HAZ
2. Solidification cracking in the weld metal
3. Hydrogen cracking in the weld metal
4. Lamellar tearing in the weld metal
14. Which electrode deposits weld metal with the greatest ductility and resistance to cracking?
1.
1. Rutile.
2. Cellulosic.
3. Basic.
4. Oxidizing.
15. In positional MMA welding on pipework, welders are having difficulty in obtaining good capping
profiles when welding in the overhead position. Would you;
1.
1. Advise them to increase the current.
2. Advise them to increase the voltage.
3. Ask for a new welding team.
4. Suggest the use of a smaller diameter electrode.
16. A common gas mixture used in MIG welding nickel alloys, to combine good levels of penetration
with good arc stability would be;
1.
1. 75% argon and 25% CO2
2. 100% argon
3. 80% argon and 20% CO2
4. 98% argon and 2% CO2
17. MMA welding of low alloy steels is more likely to be performed with;
1.
1. Cellulosic electrodes.
2. Rutile electrodes.
3. Iron oxide electrodes
4. Basic hydrogen controlled electrodes
18. Which of the following tests would indicate the toughness of weld metal/parent metal – HAZ?
1.
1. Tensile Test
2. Root bend Test
3. Hardness Test
4. Charpy v-notch
19. Pre-heating of carbon steel in manual metal arc welding is carried out to minimize the risk of;
1.
1. Parent metal cracking
2. Scattered porosity
3. Undercut
4. Lack of fusion
20. Hot shortness is a term used to indicate;
1.
1. Underfill
2. Solidification cracking
3. Hydrogen induced cracking
4. Hot crack
21. In the welding of austenitic stainless steels, the electrode and plate materials are often specified to
be low carbon content. The reason for this;
1.
1. To prevent the formation of chromium carbides
2. Minimize distortion
3. To prevent cracking in the weld
4. All of the above
22. Is it permissible to allow a single pass butt weld to cool down between weld passes?
1.
1. It depends on the specification requirements
2. It is allowed if welding is carried out in a hot and humid environment
3. It depends on the condition of HAZ
4. All of the above
23. Why shielding of arc is required during an arc welding process?
1.
1. To protect the weld pool from hydrogen, helium, and molybdenum
2. To protect the HAZ region
3. To protect the weld pool from the atmosphere
4. All of the above
24. Which of the following defects would show up as light indications on a radiograph?
1.
1. Tungsten inclusion
2. Lack of penetration
3. Excessive cap height and incomplete root penetration
4. All of the above
25. While doing a pipe to pipe weld (circumferential seam), 610mm diameter with no internal access,
which of the following techniques is most likely to be used, considering radiography using x-ray;
1.
1. SWSI
2. DWSI
3. SWSI – Y
4. SWSI – X
26. A fatigue cracks fracture surface is;
1.
1. Hill top
2. Smooth
3. Zig saw fit
4. None of the above
27. Which of the following elements, if present in significant quantities in steel, may lead to cold
shortness;
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
1.
1.
2.
3.
4.
Phosphorus
Sulphur
Silicon
Copper + Nickel
28. Lamellar tearing has occurred in a steel fabrication before welding could, which of the following
test methods could have detected it?
Ultrasonic Testing
Radiographic testing
Magnetic particle
It could not be found by any testing method
29. The strength of the fillet weld is primarily controlled by;
Leg length
Throat thickness
Weld thickness
All of the above
30. Which of the following welding processes/technique is likely to be used for the repair welding of
localized porosity in a butt weld;
MMA, Submerged arc
Mechanised MAG
All of the above
None of the above
1. Stress relieving is not helpful in which of the following cases?
1.
1.
2.
3.
4.
Softening the steel
Lowering the peak residual stress
Improving resistance to stress corrosion cracking
Improving dimensional stability after machining
2. Stray arcing may be regarded as a serious defect because:
1.
2.
3.
4.
It may reduce the thickness dimension of a component
It may cause liquation cracks
It may cause hard zones
All the above
3. Slag inclusions would occur with:
1.
2.
3.
4.
Shielded metal arc Welding
Metal inert gas Welding
Undercut and underfill
Lack of Penetration
4. Stress relieving is not helpful in which of the following cases?
1.
2.
3.
4.
In improving resistance to stress corrosion
In lowering the peak residual stresses
In softening the metal
In improving dimensional stability after machining
5. Submerged arc utilities:
1.
2.
3.
4.
Heat lost in the environment
Flat (PA) welding only.
Deep penetration characteristic
None of the above.
6. The most serious type of defect (s) is (are);
1.
2.
3.
4.
Lack of penetration
Cracks
Lack of fusion
All the above
7. When ‘hydrogen control’ is specified for a Shielded metal arc welding project, the electrode would normally be;
1.
1.
1.
1.
1.
1.
1.
Cellulosic
2.
3.
4.
Iron oxide
Acid
Basic
8. When manual metal arc welding is being carried out on an open construction site, which group of welders are most likely to require continuous
monitoring?
1.
2.
3.
4.
Concrete shuttering welding teams
Pipe welding teams
Expert riggers and foremen
Operation In-Charge
9. A low hydrogen electrode, according to BS 639, would contain:
1.
2.
3.
4.
No hydrogen.
Less than 15 ml of hydrogen per 100 grams of deposited weld metal
Less than 15 ml of hydrogen per 1000 grams of deposited weld metal
More than 15 ml of hydrogen per 100 grams of deposited weld metal
10. Two low carbon steel pipes, 150mm diameter and 6mm wall thickness, are to be butt welded using the TIG process. To ensure a full strength
joint, which of the following preps is most suitable?
1.
2.
3.
4.
Open single bevel
Open single V
Open square preparation
All of the above
11. Macroscopic examination requires any specimen to be inspected:
1.
2.
3.
4.
Once, after etching
Twice, before and after etching
No need to inspect before etching
None of the above
12. In a fatigue failure the appearance of the fracture surface is characteristic. It would be;
1.
2.
3.
4.
Rough and torn
‘Chevron’-like
Smooth
None of the above
13. Toe blending is important as it may affect;
1.
2.
3.
4.
Corrosion
Fatigue life
Overlap type defects
All the above
14. Undercut is normally assessed by;
1.
2.
3.
4.
Its depth
Its length
It’s blending
All the above
15. Welds made with high heat inputs show a reduction in which of the following properties?
1.
2.
3.
4.
Ductility
Toughness
Fatigue strength
Mechanical strength
16. If pipe bores are not matched correctly it can result in:
1.
2.
3.
4.
Lack of root penetration
Incorrect flow of water
Excessive undercut
High preheating during welding
17. In Shielded metal arc welding of low carbon steel, which electrode flux will yield greatest degree of penetration?
1.
2.
3.
4.
Iron powder
Rutile
Cellulosic
Low hydrogen
18. The most common type of defect found in a structure which is in operation for a longer period of time;
1.
2.
3.
4.
Fatigue cracking
Crystallisation
Cold Cracking
Stress gradient
19. The weld dimension used to indicate the minimum strength of a fillet weld is:
1.
2.
3.
4.
Leg length
Throat thickness
Width of bead
Length of weld element
20. You would certainly recognise a hydrogen controlled flux covered electrode from its:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Colour
Length
Trade name
BS639/AWS code letter
21. Basic coated electrodes possess which of the following properties
1.
1.
2.
3.
4.
High mechanical properties may be used to produce welds of high deposition rates and to produce welds of low hydrogen content
Low hydrogen content welds, good stop/start properties and high strength
Low carbon content welds, friable slag and high strength
All of the above
22. Which is the hardest part of a multi-pass welded joint, considering no post weld heat treatment has been done?
1.
2.
3.
4.
The HAZ of the cap
The HAZ of the root
The root
The root, and cap
23. Which of the following is applicable to a plate lamination
1.
2.
3.
4.
They originate in the parent material
They are mainly caused by hydrogen entrapment
Both 1 & 2
None of the above
24. A black triangular flag used in conjunction with a weld symbol as to en 22553 means:
1.
2.
3.
4.
Be cautious while welding
Only E 7018 to be used
Welding to be carried out on site (field weld)
All of the above
25. Which of the following is likely to be considered an essential variable on a welding procedure
1.
2.
3.
4.
A change in welding position from Vertical to Overhead
A change from an electrode classified to AWS E 6012 to an electrode E 7018
A change in preheat tem from 1100 C to 1650 C
All of the above
26. Which of the following flame types would you expect to be used for the cutting of mild steel?
1.
2.
3.
4.
Neutral flame
Carburising flame
Oxidizing flame
None of the above
27. Which of the following is used for a crater crack?
1.
2.
3.
4.
Tearing
Fatigue crack
Star crack
Lap
28. Cold lapping is another term for:
1.
2.
3.
4.
Lack of fusion at the toe of a weld
lack fusion between weld metal and HAZ
undercut on root pass
both a and b
29. The throat thickness of a ¾ inch fillet weld is?
1.
2.
3.
4.
27.5mm
24mm
13.5mm
12.5mm
30. To test a component for vibrational loading, a suitable mechanical test would be:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Fatigue
Impact
Compressive
Tensile
1. Overlap in welds could be influenced by:
1.
1.
2.
3.
4.
Welding process
Welding position
Poor welding technique
All the above
2. In MAG/CO2 welding which parameter gives the greatest control of weld appearance during dip transfer or short-circuiting welding?
1.
2.
3.
4.
Wire stick-out length
Welder’s convenience
Wire feed speed
Inductance
3. In X-ray work the quality of the radiographic image is assessed by the:
1.
1.
1.
2.
3.
4.
Density of the film
IQI indicator
KVA available
Stand-off distance
4. In Shielded Metal arc welding what parameter is used for control of penetration into the base material?
1.
2.
3.
4.
Voltage
Welding speed
Gravitational pull of the earth
Current
5. Welds made with a damaged electrode coatings in Shielded metal arc welding will lead to:
1.
2.
3.
4.
Porosity
Undercut
Excessive penetration
Excessive bead height
6. What is the most common cause of failure in root bend tests?
1.
2.
3.
4.
Improper mandrel setting
Improper electrode holder
Lack of fusion and penetration
Too high a travel speed
7. When a steel is heated to above its upper critical temperature, the structure produced is:
1.
2.
3.
4.
Martensite
Austenite
Pearlite
Ferrite
8. Which of the following can arise from copper inclusions in a mild steel weld?
1.
2.
3.
4.
Weld metal cracks
HAZ cracks
Lack of fusion
Porosity
9. An electro slag weld requires what heat treatment to improve the grain structure?
1.
2.
3.
4.
Annealing
Stress relieving
Normalising
Quench and tempering
10. An austenitic stainless steel may suffer:
1.
2.
3.
4.
Weld decay
Sensitisation
Solidification cracking
All the above
11. Ultrasonics would be preferred over radiography due to:
1.
2.
3.
4.
Ability to find most defects
Lower skill requirement
Ability to detect laminations
Both a and c
12. Generally the most suitable method of detecting lack of sidewall fusion would be:
1.
2.
3.
4.
Ultrasonic Test
MPI
Radiography
Penetrant inspection
13. Repair welding is often more difficult than production welding due to:
1.
2.
3.
4.
The material being ingrained with in-service contaminants
Restricted access within the repair area
The possible position of the weld repair
All the above
14. Flame cut preparations may, during welding, increase the likelihood of:
1.
2.
3.
4.
Cracking
Misalignment problems
Inclusions
All the above
15. A welding procedure is useful to:
1.
2.
3.
4.
Give information to the welder
Give information to the inspector
Produce sound welds
All the above
16. From the following electrode coding E50 4 B 160 20 H5, the compulsory part is:
1.
2.
3.
4.
E50 4 B 160 20 H5
B 160 20 H5
E50 4 B
None of the above
17. When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is called for. This is to:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Prevent oxidation
Prevent under bead cracking
Prevent porosity
Control the penetration bead shape
18. A welder qualification test is to verify:
1.
2.
3.
4.
Skill of the welder
The quality of the materials
The non-destructive test procedures
The manufacturing method
19. The unit of Joules would be used to measure:
1.
2.
3.
4.
Tensile strength
Impact energy
Hardness
Electrical resistance
20. Submerged arc welding is a process that generally gives:
1.
2.
3.
4.
Slag free welds
Low penetration
Low dilution
High heat input
21. When measuring the welding parameters with the MMA welding (SMAW) process for the purpose of approval of welding procedure, the
Welding inspector should measure the voltage:
1.
2.
3.
4.
As close to the welding arc as possible
Anywhere along the welding cable
Always from the voltmeter on the welding plant
As near to the welding terminals as possible
22. In arc welding process, which of the following is the correct term used for the amount of weld metal deposited per minute?
1.
2.
3.
4.
Filling rate
Deposition rate
Weld deposition
All of the above
23. Which electrode is most suitable for welding of low alloy steels with MMA welding process:
1.
2.
3.
4.
Basic hydrogen controlled electrodes
Rutile electrodes
Cellulosic Electrodes
Iron powder electrodes
24. Initiation of a TIG arc by using a High Frequency (HF) spark may not be allowed for some application because
1.
2.
3.
4.
It can damage electronic equipment
It causes tungsten inclusion
It is an electrical safety hazard
All of the above
25. Which of the following is likely to give the highest impact strength in ferritic weld metal?
1.
2.
3.
4.
Basic coated normal metal arc electrodes
Cellulosic electrodes
Both A and B
Neither A nor B
26. Which type of power source characteristics is normally used for manual welding?
1.
2.
3.
4.
Constant welding
Flat characteristics
Constant current
A motor generator
27. You suspected that ferritic steel plates, which have been edge, prepared contain crack in the prepared edges. Which NDT method would you
use to check this?
1.
2.
3.
4.
Radiography
Magnetic particle
Penetrants
Ultrasonic flaw detector
28. When hydrogen control is specified for a manual metal arc-welding project the electrode would normally be:
1.
2.
3.
4.
Cellulosic
Iron oxide
Acid
Basic
29. The steel composition in structural contract is changed form 0.15% carbon, 0.6% manganese, to 0.2% carbon, 1.2% manganese. Might this
influence the incidence of?
1.
2.
3.
4.
Cracking in the weld area
Porosity
Under cut for fillet welds
All of the above
30. For open site manual metal arc welding the following equipment is available. Which would you choose for safe working?
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
Diesel engine driven motor generator
2.
3.
4.
Single operator transformer
Multi operator transformers
All of the above
1.
Which of the following does not require baking;
1.
1.
2.
3.
4.
E 6010
E 7018
Both a & b
None of the above
2. Gamma rays and X-rays are part of a family of waves called
1.
2.
3.
4.
Acoustic waves
Light waves
Electromagnetic waves
Transverse waves
3. Why is hot – pass so-called?
1.
2.
3.
4.
Because it is applied at a high amperage
Because it is applied when the root is still hot
Because it could cause ‘hot – shortness’
Because it heat treats the root
4. To weld a carbon steel which electrode will give the greatest deposition rate in SMAW?
1.
2.
3.
4.
2% Hydrogen
Cellulosic
Iron powder
Rutile
5. Tempering is often carried out to regain toughness after which of the following processes?
1.
2.
3.
4.
Normalising
Annealing
Hardening
Dwelling
6. Incomplete root penetration in a butt joint could be caused by:
1.
2.
3.
4.
Excessive root face width
Excessive root gap and depth
Low current setting
Both A and C
7. Welding a steel plate with a CE of 0.45 would require preheating to:
1.
2.
3.
4.
Prevent the formation of chlorides
Prevent hardening in the HAZ
Prevent distortion
Save weld time
8. Pipe welding codes are set up by
1.
2.
3.
4.
Welding Inspector
Head of the state
Associations, societies, insurance companies, manufacturers and the military.
Company CEO
9. A fabricating procedure calls for fillet welds to be ‘blended in’ by grinding. This influences
1.
2.
3.
4.
Tensile strength
Fatigue life
Resistance to load
Yield strength
10. You see a welder using an oxy-acetylene flame with a long feathered inner cone. What would be the effect of this on carbon steel?
1.
2.
3.
4.
The weld would be hard and brittle
The weld could bulge
Reinforcement could be higher than usual
Underfill and spatters would be comparatively more
11. During TIG welding of austenitic stainless steel pipe, argon gas backing is used to;
1.
2.
3.
4.
Prevent oxidation
Prevent linear indication
Prevent blow holes
None of the above
12. You notice manual metal arc electrodes, stripped of flux, are being used as filler wire for TIG welding. You would object because:
1.
2.
3.
4.
It is too expensive
The wire would be too thick
The metal composition may be wrong
The wire is too short
13. Which gas to be used for shielding while doing welding of aluminium alloys by TIG welding?
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
Nitrogen
Carbon dioxide
3.
4.
Argon/carbon dioxide mixture
Argon
14. In the welding of a butt joint from one side, the profile of the root bead is controlled by
1.
2.
3.
4.
Bevel angle
Root face
Root gap
All of the above
15. Which one of the following types of steel would give rise to the formation of porosity when welded with an arc process?
1.
2.
3.
4.
Fine grained steel
Fully killed steel
Semi killed steel
Rimming steel
16. The most common type of failure associated with sharp fillets, notches and undercut is
1.
2.
3.
4.
Cree
Fatigue
Corrosion
Sudden bend
17. Low alloy steels with a high carbon equivalent will require …………. before welding
1.
2.
3.
4.
No pre-heating
High pre-heat temperatures
Low pre-heat temperatures
None of the above
18. When open site working, serious porosity in metal arc welds is brought to your attention. What would you investigate?
1.
2.
3.
4.
Electrode type
Power plant type
Electrode storage
Day temperature
19. A root bend test is used to test the amount of weld:
1.
2.
3.
4.
Ductility
Degree of freedom
Hardness
Crack orientation
20. The second run in a three run butt weld using the stovepipe technique is known as the
1.
2.
3.
4.
Sealing run
Hot pass
Intermediate run
Capping
21. In MAG/CO2 welding, which parameters give the greatest control of weld appearance during dip transfers or short-circuiting welding?
1.
2.
3.
4.
Wire sick-out length
Amperage
Wire feed speed
Inductance
22. What constituent is needed in coating of electrode of an electrode to prevent formation of porosity in welding of rimming steel?
1.
2.
3.
4.
Iron powder
Calcium fluoride
Calcium carbonate
Silicon
23. In the welding of Austenitic stainless steels, the electrode and plate material can be purchased with low carbon contents. The reason for this is
to prevent?
1.
2.
3.
4.
Cracking I the HAZ
The formation of chromium carbides
Cracking in the weld metal
Distortion
24. Incomplete penetration in a butt joint could be caused by:
1.
2.
3.
4.
Excessive root face width
Excessive root gap size
Low current setting
Both A & C
25. The planar defect is:
1.
2.
3.
4.
Incomplete fusion defects
Slag inclusion
Incomplete penetration
Both A & C
26. The main causes of porosity in welded joints are:
1.
2.
3.
4.
Poor access
Loss of gas shield
“Dirty” materials
All of the above
27. A fatigue failure characteristic by the appearance of the fracture surface. It would be:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Rough and torn
Smooth
Both A and B
Neither A and B
28. A metallurgical problem most associated with submerged arc welding is:
1.
2.
3.
4.
Hydrogen cracking in HAZ
Solidification cracking in the weld metal
Hydrogen cracking in the weld metal
Lamellar tearing in the weld metal
29. In welding procedure term, a change in essential variable means
1.
2.
3.
4.
Re-qualification of the welding procedure
Possible change in the weld’s microstructure
Possible change in t he mechanical properties
All of the above
30. Ultrasonic test is preferred over radiography due to:
1.
1.
1.
1.
2.
3.
4.
The ability to detect laminations
The ability to find more defects
Less cost
Both a and c
1.
Which of the following NDT methods can only detect surface breaking defects?
1.
1.
2.
3.
4.
MPI
DPI
UT
RT
2. Which of the following is applicable to electrode efficiency?
1.
2.
3.
4.
The mass of metal deposited as a percentage of the mass core wire melted
Iron powder electrodes have efficiencies above 100%
Electrodes of high efficiencies tend to procedure welds of a smooth flat profile
Both a and b
3. Cellulose electrodes have which of the following properties?
1.
2.
3.
4.
Viscous slag, large volumes of shielding gas and UTS values above 90,000 PSI
Large volumes of shielding gas, hydrogen contents>15 ml per 100g of weld metal deposited and should be never baked
Large volumes of shielding gas, high spatter contents and hydrogen levels < 15 ml per 100g of weld metal deposited
None of the above
4. Drooping characteristic power source is suitable for
1.
2.
3.
4.
TIG and MMA
MIG and TIG
TIG and PAW
All of the above
5. What is a weld junction?
1.
2.
3.
4.
The area containing the HAZ and the weld metal
The boundary between the fusion zone and the HAZ
Both 1 and 2
None of the above
6. The likelihood of a brittle fracture in steels will increase with
1.
2.
3.
4.
A slow cooling rate
A reduction in-service tem to sub-zero conditions
Both 1 and 2
All of the above
7. A common gas/mixture used in MIG welding of nickel alloys to combine good levels of penetration with good arc stability would be :
1.
2.
3.
4.
100% CO2
100% argon
80% argon 20%CO2
98% argon 2% oxygen
8. When visually inspecting a completed single V-butt weld cap you would certainly assess
1.
2.
3.
4.
cap height
toe blend
weld width
All of the above
9.
What two functions in arc welding must be in equilibrium to enable a stable arc to be established?
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
Arc voltage
Current
3.
4.
Wire-electrode feed rate
Metal burn- off rate
10. Which of the following destructive tests is not normally required for welder performance test?
1.
2.
3.
4.
Bend tests
Macro examination
Impact tests
Fracture tests
11. In the welding of austenitic pipe work, the bore is usually purged with argon to
1.
2.
3.
4.
Prevent formation of porosity in the weld
Prevent burn-through in the root run
Prevent oxidation of the root bead
None of the above
12. MIG welded joints are susceptible to lack of fusion problems. Due to
1.
2.
3.
4.
Poor maintenance of equipment
Incorrect settings
Poor inter-run cleaning
All the above
13. Reason for Incomplete penetration in a single ‘V’ butt joint could be
1.
2.
3.
4.
Root gap too large
Root gap too small
Step up rectifier
High heat input
14. During examination of a aluminium weld joint, macro etching may reveal:
1.
2.
3.
4.
Weld defect
Weld decay
Linear indications
Lack of inter-run penetration
15. What type of power characteristic is required for manual welding?
1.
2.
3.
4.
Constant voltage
DC generator
Drooping characteristic
None of the above
16. Excessively high voltage in submerged arc welding would result in:
1.
2.
3.
4.
Lack of fusion and spatters
Excessive flux melting
Slag removal difficulties
None of the above
17. Undercut is principally caused by:
1.
2.
3.
4.
Excessive amps
Excessive volts
Excessive travel speed
All the above
18. Which electrode classification would be relevant to AWS A5.1-81?
1.
2.
3.
4.
E 6013
E 5133
E 7018 – G
None of the above
19. Hydrogen controlled electrodes were developed principally for
1.
2.
3.
4.
The prevention of porosity
The prevention of cracking
Replacing the costly electrodes
None of the above
20. E6014 electrode would most probably used for welding
1.
2.
3.
4.
Low pressure pipework
High- pressure pipework
Vertical down welding in heat exchange
When low hydrogen welds are required
21. For welding of carbon steel with thickness more than 100 mm, which of the following welding processes would be the most suited?
1.
2.
3.
4.
TIG
Electro-slag
Manual metal arc
Plasma arc
22. Lap joints would have a
1.
2.
3.
4.
fillet weld
corner joint
butt-weld with single V
single-bevel butts with long edges
23. Cold lapping is used for
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
Lack of fusion at the toe of a weld
2.
3.
4.
Overlap
Cold cracking
Both a and b
24. ‘Toe blending’ is important as it may affect
1.
2.
3.
4.
Corrosion
Fatigue life
Both a and b
All of the above
25. A welding procedure is useful to :
1.
2.
3.
4.
Give information to the welder
Give information to the inspector
Give ‘confidence’ to a product
All of the above
26. The inclusion of an inductance in the welding circuit when using MIG/MAG welding process is to ;
1.
2.
3.
4.
Control the rate of patter in the dip transfer mode
Enable the welder to weld in position with the spray transfer mode
Both a and b
None of the above
27. Welding flux
1.
2.
3.
4.
Melts the base metal
Protects the weld pool from atmospheric contamination
Both a and b
None of the above
28. In a bend test the face of the specimen is in tension and the root is in compression. What type of test is being carried out?
1.
2.
3.
4.
Root bend test
Side bend test
Face bend test
None of the above
29.The British code for visual inspection requirements is:
1.
2.
3.
4.
BS 4872
BS 499
BS 4870
None of the above
30. With respect to welding procedure specification (WPS), a change in essential variable will lead to
1.
2.
3.
4.
Re-qualification of the weld procedure.
Possible changes in the weld’s microstructure.
Possible changes in the mechanical properties.
All the above
31. The steel composition in a structural contract is changed from 0.15% carbon 0.6% manganese, to 0.2% carbon 1.2% manganese. This might
influence the incidence of:
1.
2.
3.
4.
Heavy porosity with blow holes
Cracking in the weld area
Underfill in filler pass
Lack of fusion
32. The predominant structure of an hyper-eutectoid steel that has been quenched at above its upper critical point will be:
1.
2.
3.
4.
Austenite
Martensite
Ferrite
Sorbite
33. Which of the following steels is likely to be more susceptible to hydrogen cracking?
1.
2.
3.
4.
Carbon equivalent of less than 0.15 %
Carbon equivalent of 0.25%
Carbon equivalent of 0.18%
Carbon equivalent of 0.43%
34. A correctly made tack weld should slope from the middle to the ends in order to:
1.
2.
3.
4.
Aid better penetration at the join-up
Prevent porosity
Both a and b
None of the above
35. The use of flux with gas shielded metal arc welding allows:
1.
2.
3.
4.
Sheet metal to be welded
A stable arc when using high current densities
Aluminium to be welded
Less dilution of the weld by the parent metal
36. A steel described as QT will have improved tensile properties because it has been
1.
2.
3.
4.
Been heat-treated
Been quality tested
Both a and b
None of the above
37. In the submerged arc welding process, the use of excessive high voltages would result in?
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Insufficient flux melting
Excessive flux melting
Slag removal difficulties
Excessive spatter
38. What does the 70 represent on an E70 10 AWS A5.1 classified electrode?
1.
2.
3.
4.
70 n//mm2 min UTS
70 grade steel
70,000 P.S.I min yield strength
70,000 PSI min UTS
39. Which element in steel if present in significant amounts may lead to hot shortness
1.
2.
3.
4.
Phosphorus
Manganese
Sulphur
None of the above
40. Which of the following elements if present in significant quantities in steel may lead to cold shortness
1.
1.
1.
1.
2.
3.
4.
Calcium
Phosphorus
Hydrogen
Copper
1. Which of the following processes joins metals plastically?
1.
1.
2.
3.
4.
Friction welding
Resistance welding
Plasma welding
None of the above
2. In submerged arc welding, excessive arc voltage may cause?
1.
2.
3.
4.
Excessive penetration
Change in weld metal composition
Narrow weld width
All of the above
3. In a tensile test, a brittle material would be indicated if the fracture surface?
1.
2.
3.
4.
Shows a reduction in size
Is flat and featureless
Breaks in the weld metal
Breaks in the parent metal
4. If steel attains improved creep properties at elevated temp, which one of the following elements would have helped in doing so?
1.
2.
3.
4.
Tungsten
Manganese
Molybdenum
Carbon
5. Macroscopic exam requires any specimen to be inspected
1.
2.
3.
4.
Twice after etching
Twice, before and after etching
Twice before etching
All of the above
6. Which of the following could be expected due to the presence of iron sulphide in the weld metal?
1.
2.
3.
4.
solidification cracking
hydrogen cracking
Undercut and under fill
Weld depression
7. Incomplete root penetration in a butt joint could be caused by:
1.
2.
3.
4.
excessive root face width
excessive root gap size
low current setting
both 1 and 3
8. If the procedure doesn’t mention the requirements for visual inspection of a specimen then what should you do?
1.
2.
3.
4.
Carry out normal visual inspection
Seek advice from higher authority
Carry out no visual inspection
Re- write the requirements of the specification
9. Chromium, when added to steel as an alloying element, has the effect of making the alloy more:
1.
1.
1.
1.
1.
1.
1.
1.
1.
Ductile
2.
3.
4.
Plastic
Hardenable
Malleable
10. When a steel suffers hot shortness, it is mostly due to the presence of:
1.
2.
3.
4.
Sulphur
Phosphorous
Silicon
Manganese
11. A discontinuity can be called as defect only when
1.
2.
3.
4.
It is a Linear indication
It is a rounded indication
It exceeds the code limit
None of the above
12. You have a macro section of a ‘T’ butt joint that shows a step-like defect lying outside the visible HAZ. What would this defect possibly signify?
1.
2.
3.
4.
HAZ cracking
Toe cracking
Lamination
Lamellar tearing
13. The important point of high temperature steels is that:
1.
2.
3.
4.
They can withstand creep failure
They may suffer re-heat cracking problems
They may suffer loss of toughness
All the above
14. A basic electrode would normally:
1.
2.
3.
4.
Have superior mechanical properties
Require baking before use
Both 1 and 2
Neither 1 nor 2
15. Hot shortness is a term used to indicate:
1.
2.
3.
4.
Lamellar tearing
Solidification cracking
Hydrogen cracking
None of the above
16. Which defect would you expect to get in TIG welds in non-deoxidised steel?
1.
2.
3.
4.
Underfill and high reinforcements
Porosity
Tungsten inclusions
Spatters
17. The overall length of a pipeline can be affected by:
1.
2.
3.
4.
Longitudinal shrinkage
Angular shrinkage
Circumferential shrinkage
All of the above
18. Which one of the following is not helpful in minimising angular distortion during welding?
1.
2.
3.
4.
Use of double ‘V’ weld prep using balanced welding technique
Pre-setting of work piece
Applying post weld heat soak
All of the above
19. Percentage elongation of a metal undergoing a tensile test is a measure of:
1.
2.
3.
4.
Elasticity
Plasticity
Ductility
None of the above
20. Argon purging on the root side is necessary in the TIG welding of stainless steel to:
1.
2.
3.
4.
Avoid porosity in the root
Obtain full penetration
Obtain full fusion
All of the above
21. The toes of the cap on a butt weld:
1.
2.
3.
4.
Must overlap on the external surface of a pipe or plate by at least 1.5mm
Must be grounded
Must not be grounded
None of the above
22. Why is hot – pass so-called?
1.
2.
3.
4.
Because it is applied at a high amperage
Because it is applied when the root is still hot
Because it could cause ‘hot – shortness’
Because it heat treats the root
23. Is it permissible to allow a single ‘V’ butt weld to cool down passes?
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
It is solely the decision of the welder
It depends on the requirement of the procedure and specifications
It is solely the decision of the welding inspector
No, all welds should be completed before dropping the temperature to ambient
24. Fluctuating load is: cyclic stresses, below the UTS on a weld component may lead to:
1.
2.
3.
4.
Tensile failure
Yield failure
Fatigue failure
Shear failure
25. To measure accurately the root radius of a charpy or Izod specimen, which of the following can be used?
1.
1.
1.
2.
3.
4.
A shadowgraph
A Steel rule
A Vernier caliper
Steel Tape
1. Which of the following butt weld preparations is generally most susceptible to lack of side wall fusion during MMA welding?
1.
1.
2.
3.
4.
A “U” preparation
A “V” preparation
A Double V preparation
All of the above
2. Which of the following units is used for charpy V notch energy?
1.
2.
3.
4.
Pounds per square inch
Joules
KSi
All of the above
3. What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a weld?
1.
2.
3.
4.
Volumetric test at HAZ area
Side bend test
Tensile test
Macro test
4. Stress can be measured in:
1.
2.
3.
4.
N/mm2
Psi
mm
both a & b
5. What is the ratio between the leg length and the design throat thickness on a miter fillet weld with equal leg lengths
1.
2.
3.
4.
1 to1
2 to 1
1.414 to 1
All of the above
6. The primary duty of a welding inspector is:
1.
2.
3.
4.
to ensure the welds are defect free
to ensure the weld is free from residual stresses
to write job specifications
to ensure all welding and associated activities are carried out in accordance with the procedure and specification
7. Quality Assurance:
1.
2.
3.
4.
Another name for inspection
Relates to all activities and functions concerned with the attainment of quality
Is the activity of ensuring documents related to specific contracts are in order
Is the activity of carrying out quality control
8. Generally speaking, a welding inspector, as a minimum requirement:
1.
2.
3.
4.
Must have a thorough knowledge of NDT
Must know how to interpret radiographs
Must have thorough knowledge of welding metallurgy
None of the above
9. The toes of the cap of a butt weld
1.
2.
3.
4.
Must overlap onto the external surface of a plate or a pipe by at least 1.5mm
Must be ground
Must never be ground
None of the above
10. A welding inspector:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
4.
Should be able to weld
Must know how to interpret radiographs
May be required on certain contracts, to interpret radiographs
None of the above
11. What is the throat thickness of a fillet weld
1.
1.
2.
3.
4.
The distance from the toe to the face
The distance from the root to the face center
The distance from the root to the toe
The distance from toe to toe
12. Stress acting in the opposite direction of compressive stress is known as:
1.
2.
3.
4.
Tensile stress
Shear stress
Hoop stress
All of the above
13. A weld defect is
1.
2.
3.
4.
A flaw of any size or type
An indication which can be seen by visual inspection
An imperfection with a dimension above the specified limit
An indication shown by surface or volumetric NDT
14. The fusion boundary of a weldment is
1.
2.
3.
4.
The boundary between weld metal and HAZ
The boundary between different passes
Both 1 and 2
Neither 1 nor 2
15. Which group of welders is most likely to require continuous monitoring by a welding inspector?
1.
2.
3.
4.
Concrete shuttering welders
Overland pipeline welders
Tack welders
Maintenance welders
16. Which of the following destructive tests would indicate the toughness of weld metal/parent
1.
2.
3.
4.
Tensile test
Ultrasonic test
Side bend test
Charpy V notch test
17. Fillet welds are:
1.
2.
3.
4.
Preferable to butt welds due to high strength
Difficult to assess with NDT in comparison with butt (groove) welds
Used only for appearance purposes
All of the above
18. API stands for:
1.
2.
3.
4.
Associated pipeline industries
American pipeline institute
American petroleum institute
American pressure pipe institute
19. What is the leg length of a fillet weld
1.
2.
3.
4.
Between 1 mm to 3 mm
The distance from the root to the face center
The distance from the root to the toe
The distance from the one toe to other
20. Which of the following alloys is non-magnetic ?
1.
2.
3.
4.
4.0% chromium molybdenum
12.0% chromium 1.5% molybdenum
Austenitic stainless steel
9.0% nickel steel
21. If submerged arc welding is used to make butt welds, which would you be most critical of?
1.
2.
3.
4.
The root gap tolerance
The angle of preparation
Both 1 & 2
Neither 1 & 2
22. Which one of the following statements is correct?
1.
2.
3.
4.
Preheating increases dilution
Preheating increases cooling
Both 1 & 2
Neither 1 & 2
23. Proof stress is used when non-ferrous metals are undergoing tensile tests to determine the equivalent:
1.
2.
3.
4.
Elasticity
Yield strength
Tensile strength
All of the above
24. One purpose of a microscopic examination of a weld is to establish the:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
3.
Strength of the weld
Number of alloying elements
Grain size
4.
Number of runs used
25. Nick break specimen test is carried out for:
1.
2.
3.
4.
Soundness and fracture appearance
Tensile strength and fracture appearance
Ductility and fracture appearance
All of the above
26. Submerged arc welds made with re-cycled flux are liable to:
1.
2.
3.
4.
Porosity
Underfill and spatters
Incomplete fusion
All of the above
27. Degreasing components is essential for quality welding but some agents may:
1.
2.
3.
4.
Cause corrosion problems
Give off phosgene gas
Leave residues
All the above
28. The weld metal deposit of MMA electrodes achieves its mechanical strength through:
1.
2.
3.
4.
The core wire
The flux coating
Iron powders with the flux coating
None of the above
29. Submerged arc fluxes can be supplied in two forms. These are:
1.
2.
3.
4.
Fused and agglomerated
Agitated and fused
Sintered and agglomerated
None of the above
30. Which of the following processes uses the ‘key holing’ system of fusion?
1.
2.
3.
4.
Friction welding
Thermit welding
Electron beam welding
All of the above
31. When visually inspecting a fillet weld it would normally be sized by:
1.
2.
3.
4.
The leg lengths
The actual throat thickness
The design throat thickness
Both 1 and 3
32. The main usage of arc cutting/gouging processes is:
1.
2.
3.
4.
The cutting of single bevel preparations
The removal of deposited welds
The cutting of single U type preparations
The cutting/gouging of non-ferrous materials only
33. Which of the following coatings is associated with stove welding?
1.
2.
3.
4.
Cellulosic
Rutile
Basic
Oxidising
34. A welding inspector’s main attribute includes:
1.
2.
3.
4.
Literacy
Knowledge and experience
Honesty and integrity
All of the above
35. Quality assurance is:
1.
2.
3.
4.
The inspection of a product or service
Not solely related to planning and inspection
The implementation of quality control
None of the above
36. Which mechanical test can be used to make an assessment of surfacing breaking defects?
1.
2.
3.
4.
Nick break test
Macro test
Bend test
All of the above
37. Gamma rays and X-rays are part of a family of waves called:
1.
2.
3.
4.
Acoustic waves
Light waves
Electromagnetic waves
Transverse waves
38. A surface breaking crack will be detected during a magnetic particle inspection if it is:
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
1.
2.
At right angles to the lines of flux
Parallel to the lines of flux
3.
4.
At 25° to the lines of flux
All the above
39. A code of practice for visual inspection should include the following:
1.
2.
3.
4.
Before, during and after welding activities
Before welding activities only
After welding activities only
None of the above
40. One advantage of metal gas arc shielded welding is:
1.
1.
1.
2.
3.
4.
Can be used in draughty locations without protection
Produces a deposit low in hydrogen content
Both 1 & 2
Neither 1 nor 2