WELDING INSPECTION AND CERTIFICATIONAWS

Module 1

Q1-1 Why is there an increasing need for weld quality?

a) Safety b) Economicsc) Less conservative designd) Government regulationse) All of the above

Q1-2 What AWS documents describe the rules for CWI certification program?

a) AWS 5.5b) AWS D1.1c) AWS QC – 1 d) AWS 5.1e) AWS 14.1

Q1-3 Weld quality control begins after welding has been initiated.

a) Trueb) False

Q1-4 What AWS document contains the CWI application form?

a) AWS D1.1b) AWS QC-Gc) AWS 5.1d) AWS Welding Handbook, Volume 1e) AWS 5.5

Q1-5 What is generally considered to be the most important quality of a welding inspector?

a) Graduation from a welding vocational programb) An engineering degreec) An associate degreed) Professional attitudee) Hold certified welder certificate

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Q1-6 The vision requirements for a CWI are:

a) 20/20 visionb) 20/40 visionc) 20/40 natural or corrected visiond) The inspector cannot wear glassese) 230/60 vision

Q1-7 The acronym “KASH” stands for:

a) Knowledge, attitude, skills and habitsb) Knowledge, application, skill and habitsc) Knowledge, attitude, skills and honestyd) Knowledge, application, skills and honestye) Knowledge, attitude, sincerity and honesty

Q1-8 The welding inspector should have a basic understanding of:

a) Welding processesb) Nondestructive testing methodsc) a and b aboved) Codes and standardse) All of the above

Q1-9 The term used to describe a delay in the production schedule to permit inspection is:

a) NDEb) Hold pointc) Pre-inspectiond) Reference pointe) Arc strike

Q1-10 Inspection report corrections should be made by:

a) Rewriting the entire reportb) Reporting the correction to the welding foremanc) Telling welder what was doned) Ignore the original errore) Single-line out the error., correct the error, date and initial

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Q1-11 A simple definition of ‘ethics’ is:

a) Using common sense and honestyb) Living by the rulesc) Being fair and impartiald) Basing decisions on factse) All of the above

Q1-12 For communication to be effective, it should form a “continuous loop”

a) Trueb) False

Q1-13 The welding inspector must often communicate with:

a) Weldersb) Supervisorsc) Welding engineersd) Members of managemente) All of the above

Q1-14 NDE personnel (other than visual) should be certified to what document?

a) QC – 1b) D1.1c) API 1104d) ASNT – TC – 1A e) Certification is not needed

Q1-15 You must have a high school diploma to become a CWI.

a) Trueb) False

Q1-16 The CWI exam has several parts; these are:

a) Fundamentals, practical, codeb) Fundamentals, basic, codec) Basic, vision test, fundamentald) Code, vision test, practicale) None of the above

Q1-17 The CWI exam requires that the D 1.1 code be used for the open book code test.

a) Trueb) False

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Q1-18 The CWI exam contains three parts, each two hour long.

a) Trueb) False

Q1-19 The title of the AWS Standard, ‘A3.0’ is:

a) Filler Metal Specificationsb) Standard Welding Terms and Definitionsc) Guide to CWI Certificationd) Requirements for CWI certificatione) None of the above

Q1-20 API Standard 1104 covers the fabrication of the cross-country bridges.

a) Trueb) False

Q1-21 Some of the approved codes/standards for the open book portion of the CWI exam are AWS D1.1, API 1104, ASME Sect ion VIII, ASME IX, ASME B31.1, MIL_STD-248D, and MIL-STD 1689 (SH)?

a) Trueb) False

Q1-22 Prior to starting s job assignment, the welding inspector should determine:

a) What code, standard, or specification appliesb) What inspections should be conductedc) When inspections should be conductedd) Where records are maintainede) All of the above

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SAFE PRACTICESAWS

Module 2Q2-1 The welding inspector is expected to which of the following safety hazards:

a) Radiation b) Falling objectsc) Electrical shocksd) Eye hazardse) All of the above

Q2-2 A document, which covers safety in welding and cutting, is:

a) AWS D1.1b) API 1104c) ANSI/ASC Z49.1d) ASME Sec VIIIe) ASME B31.3

Q2-3 The most important component of an effective safety and health program is:

a) Safety rulesb) Safety proceduresc) Protective equipmentd) Welding helmete) Management support

Q2-4 Safety training is mandated under provisions of:

a) AWS “Safe Practice”b) OSHAc) ASME Coded) Welding Handbook, Volume 2e) None of t he above

Q2-5 The abbreviation ‘MSDS’ means:

a) Management Support and Daily Safetyb) Materials Strength and Discontinuity Sheetc) Materials Safety Data Sheetd) Material Strength and Data Sheete) None of the above

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Q2-6 The abbreviation ‘TLV’ means:

a) Total Linear volumeb) Threshold Limit Valuec) Tack Length Valued) Threshold Limiting Valuee) None of the above

Q2-7 Employers must make all applicable MSDS data to their employees.

a) Trueb) False

Q2-8 Personnel must be trained to recognize hazards.

a) Trueb) False

Q2-9 A ‘Hot Work Permit” is required for:

a) All welding operations b) All cutting operationsc) All preheating operationsd) Ares where a fire hazard may occur during a welding, cutting, or preheating

operatione) All of the above

Q2-10 Eye hazard found in welding operations include:

a) Flying particlesb) Radiationc) Smoke and fumesd) All of the above

Q2-11 Protective equipment not suitable for eye protection from welding radiation includes:

a) Welding helmet with filter platesb) Clear safety gogglesc) Safety goggles with filter platesd) Protective screense) Properly positioned barricades

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Q2-12 Suitable clothing materials for welding and cutting are:

a) 65% cotton, 35% polyesterb) Woolc) Chemically treated cottond) b and c abovee) None of the above

Q2-13 Before working on equipment where machinery guards have been removed, a ‘Lock’ Tag and Try’ procedure should be completed.

a) Trueb) False

Q2-14 In avoiding fumes during welding, the most important factor is:

a) The type of base metalb) The type of filter metalc) The Type of welding processd) The position of the welding machinee) The position of the welder’s hand

Q2-15 It is not important to consider ventilation during welding and cutting operations.

a) Trueb) False

Q2-16 When entering confined spaces; a ‘standby’ is not required.

a) Trueb) False

Q2-17 Some of the toxic materials the welder may be exposed to are

a) Cadmiumb) Chromiumc) Nickeld) Leade) All of the above

Q2-18 Proper usage and handling of compressed gas cylinders include:

a) Not welding on cylindersb) Not including the cylinders in the ground or electrical circuitc) Securing them properlyd) Identifying the gas prior to usee) All of the above

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Q2-19 Acetylene becomes unstable above what pressure?

a) 5 psib) 10 psic) 15 psid) None of the above

Q2-20 Oxygen is a flammable gas

a) Trueb) False

Q2-21 Electrical currents above approximately 6 milliamperes are considered:

a) Not harmfulb) Primary currentsc) Harmfuld) Secondary currentse) b and c above

Q2-22 When operating gas cylinders, the primary valve should be opened:

a) All of the way on an acetylene cylinderb) One turn on an oxygen cylinderc) All the way on an oxygen cylinder to backseat the valved) c and d above

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METAL JOINING AND CUTTING PROCESSESAWS

Module 3

Q3-1 Which of the following is the function of the flux coating coating of a SMAW electrode?

a) Insulatingb) Alloyingc) Deoxidationd) Shieldinge) All of the above

Q3-2 In the AWS system SMAW electrode designations, the next to the last digit refers to:

a) Impact strengthb) Electrode coatingc) Welding positiond) Strengthe) None of t he above

Q3-3 Which of the following is an incorrect statement about a SMAW electrode as E7024?

a) It is a low hydrogen typeb) The weld deposit has a minimum tensile strength of 70,000 psic) It is suitable for use in the flat and horizontal fillet positions onlyd) It is an electrode for welding carbon steele) None of t he above

Q3-4 Of the following, which is not an essential part of of a typical SMAW system?

a) Constant current power supplyb) Wire feederc) Covered electroded) Electrode leade) Work (ground) lead

Q3-5 Which of the following welding problems is the result of distorted magnetic field that deflects the welding arc?

a) Cracks b) Short circuitingc) Arc blowd) Insufficient welding current

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Q3-6 Which of the following is not considered a type of a metal transfer for GMAW?

a) Short circuitingb) Sprayc) Globulard) Droplete) Pulsed arc

Q3-7 Which of the following types of metal transfer in GMAW provides the lowest amount of heat to the work piece, and therefore prone to incomplete fusion?

a) Short circuitingb) Sprayc) Globulard) Droplete) Pulsed arc

Q3-8 Which of the following gases can be used as shielded gases for GMAW?

a) Carbon dioxideb) Argon-oxygenc) Argon-carbon dioxided) Argone) All of the above

Q3-9 Which of the following is not considered as welding process?

a) SMAWb) GMAWc) FCAWd) ESWe) None of the above

Q3-10 IN the electric system for FCAW, the second digit (1) in an electrode marked (E71T-5) refers to:

a) Strengthb) Welding positionc) Chemical compositiond) Usabilitye) None of the above

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Q3-11 Which of the following is not an essential element of an FCAW system?

a) Constant voltage power supplyb) Tubular electrodec) Wire feederd) External shielding gase) Work (ground) lead

Q3-12 What aspects of the GTAW and PAW processes is difficult than for the other arc welding processes?

a) Nonconsumeable electrodeb) Power supplyc) Shieldingd) All of the abovee) None of the above

Q3-13 Shielding for the GTAW and PAW processes is different for other than arc welding processes?

a) Granular fluxb) Slagc) Inert gasd) Oxygene) None of the above

Q3-14 A green stripe on a Tungsten electrode designations:

a) Pure tungstenb) 1% thoriated tungstenc) Zirconiated tungstend) None of the above

Q3-15 When welding Aluminum with the GTAW process, what type of welding current is most commonly used?

a) DCEpb) DCENc) ACd) a and b abovee) b and c above

Q3-16 SAW and ESW processes are similar in that

a) Both are an arc welding processb) Both use shielding gasesc) Both use a granular flux, which becomes molten

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Q3-17 Solidification cracking due to improper width-to-depth ratio of the weld bead is a serious problem primarily with which welding process?

a) SMAWb) OFCc) SAWd) All of the above

Q3-18 Which of the following are not common to both GTAW and PAW?

a) Nonconsumeable tungsten electrodeb) Constricting orificec) Shielding gas nozzled) Externally applied filler metale) None of the above

Q3-19 What technique is employed with PAW to produce full penetration welds without edge preparation?

a) Stringer beadsb) Weave beadsc) Keyholed) Backstepe) None of the above

Q3-20 What welding process produces welds in a single pass, with the progression vertically upward along the joint?

a) SAWb) ESWc) FCAWd) a and b above

Q3-21 Which of the following is not an advantage of the ESW process?

a) High deposition rateb) Ease of setupc) Capable of joining thick sectionsd) No tendency for angular distortion

Q3-22 Which welding process is considered to be a chemical welding process?

a) OAWb) SWc) GMAWd) GTAWe) SMAW

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Q3-23 Brazing differs from welding in that:

a) No filler metal is usedb) An oxyfuel flame is usedc) The base metal is not meltedd) All f the above

Q3-24 For satisfactory results, a braze joint should have:

a) Clean joint surfacesb) A small clearance between pieces to be joinedc) A large surface area for the joint aread) Heat sourcee) All of the above

Q3-25 Which of the following is an advantage of brazing?

a) Ease of joining thick sections b) Ability to join dissimilar metalsc) a and b aboved) b and c above

Q3-26 Of the following metals, which cannot be efficiently, cut using OFC?

a) Methyl acetylene – propadiene (MPS)b) Propanec) Acetylened) Methane (natural gas)e) All of the above

Q3-27 Which of the following cutting processes can cut any metal?

a) OFCb) CAC-Ac) PACd) a and b abovee) b and c above

Q3-28 The width of a cut is referred to as the:

a) Gapb) Drossc) Kerfd) Drage) None of above

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Q3-29 The SMAW power supply can be:

a) DCENb) ACc) DCEPd) All of the abovee) a and c above

Q3-30 Of the following, which is a noncontact welding process, requiring no electrode and is not influenced by the presence of magnetic fields?

a) ESWb) PAWc) LBWd) a and b abovee) None of the above

Q3-31 Which of the following uses a focused beam of electrons as a heat source for fusion welding?

a) EBWb) ESWc) EGWd) a and c abovee) None of the above

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WELD JOINT GEOMETRY AND WELDING SYMBOLSAWS

Module 4

Q4-1 Which of the following is not considered a type of joint?

a) Buttb) Tc) Filletd) Cornere) Edge

Q4-2 The type of joint formed when the two pieces to be joined lie in parallel planes and their edges overlap is called?

a) Cornerb) Tc) Edged) Lape) Butt

Q4-3 That portion of single bevel butt joint where the pieces to be joined come closet together is referred to as the?

a) Radius b) Joint rootc) Bevel angled) Grove anglee) None of the above

Q4-4 In a single V-groove weld, the sloped surfaces against which the weld metal is applied are called?

a) Root faceb) Rootc) Grove facesd) Groove anglee) Bevel angle

Q4-5 The type of weld produced by filling an elongated hole in an overlapping member attaching it to the member beneath is called a?

a) Plug weldb) Spot weldc) Seam weldd) Slot welde) None of the above

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Q4-6 The type of weld configuration formed when the length of a round bar is placed parallel against a flat surface is a?

a) Double-flare-bevel-grooveb) Single-flare-Vc) Edge flanged) Corner flangee) None of the above

Q4-7 The type of weld used to build up thinned surfaces provided a layer of corrosion protection. Or provide a layer of abrasion resistant material, is referred to as a?

a) Edge weldb) Flare weldc) Flanged) Slot welde) Surfacing weld

Q4-8 The type of weld having a generally triangular cross section and which is applied to either a T, corner, or lap joint is called a?

a) Flange weldb) Flare weldc) Fillet weldd) Slot welde) Spot weld

Q4-9 In a completed groove weld, the surface of the weld on the side from which the welding was completed on the near side of a joint is called a?

a) Crownb) Weld reinforcementc) Weld faced) Roote) Cap pass

Q4-10 The type of weld applied to the opposite side of a joint before a single V-groove weld is completed on the near side of a joint is called a?

a) Melt-through weldb) Backing weldc) Back weldd) Root welde) None of the above

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Q4-11 In a completed weld, the junction between the weld face and base metal is called the?

a) Rootb) Weld edgec) Weld reinforcementd) Lege) Toe

Q4-12 The height of the weld face above the base metal in a groove weld is called the?

a) Crown b) Buildupc) Faced) Weld reinforcemente) None of the above

Q4-13 In a fillet weld, the leg and size are the same for what type of configuration?

a) Effective throatb) Concave weldc) Convex weldd) Unequal leg fillete) Oversized weld

Q4-14 When looking at the cross section of a completed groove weld, the difference between the fusion face and the weld interface is called the?

a) Depth of fusionb) Depth of penetrationc) Root penetrationd) Joint penetratione) Effective throat

Q4-15 For a concave fillet weld, which throat dimensions are the same?

a) Theoretical and effectiveb) Effective and actualc) Theoretical and actuald) All of the abovee) None of the above

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Q4-16 In a partial penetration single V-groove weld, the dimension measured from the joint root to where the weld penetration stops is?

a) Joint penetrationb) Effective throatc) Root penetration d) Depth off fusione) Weld interface

Q4-17 The size of a spot weld is determined by its?

a) Depth of fusionb) Diameter of weld at point of contactc) Depth of penetrationd) Thicknesse) None of the above

Q4-18 The primary element of any welding symbol is referred toas the?

a) Tailb) Arrowc) Reference lined) Arrow sidee) Weld symbol

Q4-19 Information appearing above the reference line refers to the?

a) Near sideb) Arrow sidec) Far sided) Other sidee) None of the above

Q4-20 The graphic description of the type of weld is called the?

a) Tailb) Welding symbolc) Weld symbold) Arrow

Q4-21 When a weld symbol is centered on the reference line, this indicates?

a) That the welder can put the weld on either side.b) That there is no side significance.c) That the designer doesn’t know where the weld should go.d) That the welder should weld in whatever positions the weld in.e) None of the above

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Q4-22 A triangular-shaped weld symbol represents what type of weld?

a) Bevel grooveb) Flare groovec) Flange grooved) V-groovee) Fillet weld

Q4-23 The first dimension appearing to the immediate right of the weld symbol generally refers to the?

a) Weld reinforcementb) Root openingc) Pitch distanced) Weld lengthe) None of the above

Q4-24 In the case of plug or slot weld, a dimension placed within the weld symbol would indicate?

a) Depth of fillingb) Slot weld widthc) Plug weld diameterd) Angle of countersinke) None of the above

Q4-25 The required spot weld ‘size’ parameter can be shown as?

a) A dimension to the right of the symbolb) A dimension of the required nugget diameterc) A value for the required strength per spotd) a and b abovee) b and c above

Q4-26 A number appearing to the right of the spot weld symbol refers to?

a) Spot weld sizeb) Spot weld lengthc) Number of spots requiredd) Pitch distance between adjacent spotse) None of the above

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Q4-27 The part of the welding symbol which an be used to convey any additional information that cannot be shown otherwise is referred to as?

a) The weld symbol b) The arrowc) The reference lined) The taile) None of the above

Q4-28 A number in parentheses just above/below the weld symbol ia a welding symbol for slot welds describes?

a) The length of weldb) The type of weldingc) The number of welds requiredd) The type of electrode to usee) None of the above

Q4-29 A number not in parenthesis to the left of the grove weld symbol in a welding symbol refers to the?

a) Depth of bevelb) The length of weldc) The weld quality standardd) The weld procedure to usee) None of the above

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DOCUMENTS GOVERNING WELDING INSPECTION AND QUALIFICATION

AWSModule 4

Q5-1 Which of the following do not contain job quality requirements?

a) Codesb) Drawingsc) Specificationsd) Textbookse) Standards

Q5-2 Of the following, which can be considered mandatory?

a) Codesb) Standardsc) Specificationsd) Drawingse) None of the above

Q5-3 The type of document that has legal status by definition is:

a) Codeb) Standardc) Specificationd) Both a and b abovee) All of the above

Q5-4 The type of document that describes the requirements for a particular material or component is referred to as:

a) Codeb) Standardc) Specificationd) A and b abovee) B and c above

Q5-5 Something set up and established by authority as a rule to measure quantity, quality, value, weight, etc.

a) Specificationb) Standardc) Coded) Drawinge) None of the above

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Q5-6 The job documents that best describe the size and configuration of a weldment are:

a) Codesb) Standardsc) Specificationsd) Drawingse) None of the above

Q5-7 Of the following types of documents, which have general acceptance in the welding industry?

a) Contracts standardsb) Specificationsc) Drawingsd) All of the above

Q5-8 The code that covers the welding of steel structures is:

a) ASME Section IXb) ASME B31.1c) API 1104d) AWS D1.1e) ASME B31.3

Q5-9 The code that covers the design of metallic unfired pressure vessels is:

a) ASME Section XIb) ASME Section VIIIc) ASME Section Xd) API 1104e) AWS D1.1

Q5-10 The series of specifications covering the requirements for welding electrodes is designated:

a) AWS D1.1b) AWS D14.Xc) AWS A5.1-A5.31d) ASTM A53e) ASTM A36

Q5-11 Which of the following methods for controlling materials is a fabrication shop, is most suitable for automation?

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a) Color codingb) Alpha-numeric codingc) Heat number transferd) Bar codinge) Segregation by alloy

Q5-12 Which Section of the ASME Code covers qualification of welders?

a) Section Vb) Section XIc) Section VIIId) Section IX

Q5-13 Tolerances are required on drawings to:

a) Guide the inspector on permissible size variationsb) Show the total amount of variation permitted from the design sizec) Both a and b aboved) None of the above

Q5-14 Tolerances can be expressed:

a) As a variation between limitsb) As plus or minus dimensionc) As a design size either plus or minusd) All of the abovee) None of the above

Q5-15 Drawing notes can be classified as:

a) Generalb) Localc) Specificationsd) All of the abovee) None of the above

Q5-16 Hold points refer to:

a) The points for lifting an objectb) A delay in fabrication to permit inspectionc) A shutdown at the end of the dayd) None of the above

Q5-17 The welding inspector I s not responsible for checking to make sure all welding and testing personnel have adequate certifications.

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a) Trueb) False

Q5-18 The American Welding Society has developed how many welding codes?

a) Oneb) Twoc) Threed) Foure) Six

Q5-19 When inspecting unfired pressure vessels to the ASME Codse, the inspector will usually use several different Sections?

a) Trueb) False

Q5-20 What Section of the ASME Code are the filler materials found?

a) Sectionb) Section II, Part Cc) Section II, Part Dd) Section IXe) None of the above

Q5-21 Standards are never considered mandatory

a) True b) False

Q5-22 Base metals used in fabrication can be bought per which of the following?

a) ASTM Standardsb) ASME Code, Section II, Part A and Bc) It is not required to specify base metald) A and b abovee) None of the above

Q5-23 The AWS Specifications designated as A5.XX refer to:

a) Filler metals b) Rules for bridgesc) Cross country pipelinesd) Pressure vessels fabrication

Q5-24 An effective material control system will:

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a) Be as simple as possibleb) Contain checks and balancesc) Not be necessary unless the fabrication is for nuclear workd) Be base on ‘first in-first out’e) a and b above

Q5-25 UNS refers to:

a) United Nondestructive Societyb) United National Standardsc) Unified National Systemd) Unified Numbering Systeme) None of the above

Q5-26 Who is normally responsible for the qualification of welding procedures and welders?

a) Welder b) Architectc) Welder’s employerd) Engineere) Code body

Q5-27 Which of the following processes is not considered prequalified in accordance with AWS D1.1?

a) Shielded metal arc b) Submerged arcc) Short-circuiting transfer gas metal arcd) Spray transfer gas metal arce) Flux cored

Q5-28 Of the following types of test specimens, which do API and not ASME for procedure and welder qualification testing use?

a) Face bendb) Root bendc) Side bendd) Nick breake) Tensile

Q5-29 What is the pipe welding position where the pipe remains fixed its axis horizontal, so the welder must weld around the joint?

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a) 1Gb) 2Gc) 5Gd) 6Ge) 6GR

Q5-30 What is the pipe welding position where the axis of the pipe lies fixed at a 45-degree angle?

a) 1Gb) 2Gc) 5Gd) 6Ge) None of the above

Q5-31 What is the pipe position test for welders who are trying to qualify to weld T, K and Y connections?

a) 1Gb) 2Gc) 5Gd) 6Ge) 6GR

Q5-32 If a welder qualifies to weld with E6010 electrode, which is an F3 group electrode, he is also qualified to weld with all of the following except:

a) E6011b) E6012c) E7018d) E7024e) E6013

Q5-33 With relation to procedure and welder qualification, which of the following can be an important task for the welding inspector?

a) Watching the welding qualification testb) Identifying samplesc) Cutting and testing specimensd) Monitoring production weldinge) All of the above

Q5-34 For most codes, if a welder continues to use particular process and procedure, how long does his qualification remain in effect?

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a) Indefinitelyb) 6 monthsc) 1 yeard) 3 yearse) Until produces a rejectable weld

METAL PROPERTIES AND DESTRUCTIVE TESTINGAWS

Page 27 of 50

Module 4

Q6-1 The property of metal that describes their resistance to indentation is called:

a) Strengthb) Toughnessc) Hardnessd) Ductilitye) None of the above

Q6-2 The property of metal that describes their ability to carry a load is:

a) Strengthb) Toughnessc) Hardnessd) Ductilitye) None of the above

Q6-3 Generally, as strength increases for carbon steels, the ductility:

a) Increasesb) Stays the samec) Decreasesd) Is not related to strengthe) None of the above

Q6-4 The property that describes the ability of a metal to deform when pressed is:

a) Strengthb) Toughnessc) Hardnessd) Ductilitye) None of the above

Q6-5 The type of strength related to a metal’s behavior when the load is applied in a cyclic manner is:

a) Tensileb) Compressivec) Torsionald) Impacte) Fatigue

Q6-6 The yield strength of a material is determined by:

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a) Impact testingb) Tensile testingc) Hardness testingd) The offset methode) b and d above

Q6-7 Which metal properties are directly related?

a) Conductivity and strengthb) Strength and ductilityc) Strength and hardnessd) Ductility and toughnesse) c and d above

Q6-8 The ability of a metal to absorb energy is called:

a) Strengthb) Ductilityc) Hardnessd) Toughnesse) None of the above

Q6-9 The metal property affected by the surface condition of the sample is:

a) Tensile strengthb) UTSc) Hardnessd) Fatigue strengthe) All of the above

Q6-10 Which of the following element is generally considered to have the most pronounced affect on the properties and performance of carbon steel?

a) Aluminumb) Carbonc) Manganesed) Chromiume) None of the above

Q6-11 Which alloying element is commonly added to steel to improve its corrosion resistance?

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a) Carbonb) Aluminumc) Silicond) Chromiume) None of the above

Q6-12 Hydrogen in the molten weld metal can cause:

a) Undercutb) Overlapc) Crackingd) Porositye) c and d above

Q6-13 Which property cannot be determined from tensile test?

a) Ultimate tensile strengthb) Percent elongationc) Percent reduction of aread) Impact strengthe) Yield strength

Q6-14 A metal’s ductility can be expressed as:

a) Percent elongationb) Percent reduction of areac) Proportional limitd) a and b abovee) b and c above

Q6-15 A tensile specimen having a cross sectional area of 0.25 square inches fails at a load of 15,250 pounds. What is the tensile strength? (Tensile Strength = Load/Area)

a) 3813 psib) 61,000 psic) 6,100 psid) 58,500 psie) None of the above

Q6-16 The point at which a metal’s behavior changes from elastic to plastic (onset of permanent deformation) is referred to as:

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a) Yield strengthb) Ultimate tensile strengthc) Modulus of elasticityd) Young’s moduluse) None of the above

Q6-17 What is the percent elongation of a specimen whose original gage length was 2 inches and final gage length was 2.5 inches?

a) 30%b) 25%c) 50%d) 40%e) None of the above

Q6-18The family of hardness tests that uses both a minor and major load is called:

a) Brinnelb) Vickersc) Rockwelld) Knoope) None of the above

Q6-19 Which of the following test are referred to as microhardness test?

a) Rockwellb) Vickersc) Knoopd) a and b abovee) b and c above

Q6-20 What type of test uses a weighted pendulum, which strikes a notched test specimen?

a) Brinnel testb) Fatigue testc) Tensile testd) Microhardness teste) Charpy impact test

Q6-21 Endurance limit is an expression used for what type of testing?

a) Fatigue

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b) Hardnessc) Soundnessd) Tensione) None of the above

Q6-22 The metal property that relates to a metal’s deforming without failing is called:

a) Tensile strengthb) Ductilityc) Hardnessd) Toughnesse) None of the above

Q6-23 Which test is not considered a ‘soundness test?

a) Hardnessb) Face bendc) Fillet breakd) Root bende) Nick break

Q6-24 The type of testing used to evaluate the type of microstructure present is a metal is called:

a) Tensileb) Hardnessc) Toughnessd) Metallographice) None of the above

Q6-25 Which of the following tests can be used to judge the soundness of a weld?

a) Nick breakb) Side bendc) Face bendd) Fillet breake) All of the above

METRIC PRACTICE FOR WELDING INSPECTIONAWS

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Module 7

Q7.1 A 50.0lb can of welding electrodes weighs how many kg?

a) 227 Kgb) 25 Kgc) 22.5 Kgd) 23,000 Kge) None of the above

Q7.2 A weld joint measured and found to be 345.0 mm long. How long is that joint in terms of inches?

a) 135 inb) 13.58 inc) 8760 ind) 876 ine) 13.0 in

Q7.3 What is the wire feed speed that is measured to be 175 in/min?

a) 0.070 m/sb) 74.1 mm/sc) 7.41 mm/sd) 70 mm/se) 75 mm/s

Q7.4 Which of the following are the proper base unit(s0 linear measurement in the system?

a) Yard b) Inchc) Footd) Milee) All of the above

Q7.5 What is the base unit for measuring mass in the SI units?

a) Meterb) Kilogramc) Mega Pascald) Litere) None of the above

Q7.6 The federal Government has initiated the requirement that all future government documents must be published using the SI system.

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a) Trueb) False

Q7.7 The metric system, or SI. Is far more complicated than the US system.

a) Trueb) False

Q7.8 Many U.S industries presently use the SI.

a) Trueb) False

Q7.9 To be most effective, the U.S worker must know which measurement system?

a) Metricb) SIc) US customaryd) All of the above

Q7.10 AWS has mandated the requirement that the metric system be used.

a) Trueb) False

Q7.11 AWS has prepared guide for aiding the transition to metrication. Its designation is:

a) D1.1b) Section VIIIc) A3.0d) A1.1e) None of the above

Q7.12 Which of the following countries are not officially on the SI system?

a) Japanb) Britainc) Mexicod) Australiae) United states

Q7.13 In the US customary system, what is the base unit ’ounce’ used to measure”

a) Mass

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b) Volumec) All of the aboved) Distance

Q7.14 The US system of measurement is based on powers of 10.

a) Trueb) False

Q7.15 Pressure and tensile strength are measured in the SI using what as the base unit?

a) Literb) Meterc) Pascald) Newtone) Hertz

Q7.16 Match the following terms with the property measured.

a. Ampere 1. Frequency = a,3b. Hertz 2. Energy = b,1c. Joule 3. Electric current = d,5d. Meter 4. Mass = c,2e. Kilogram 5. Length = e,4

Q7.17 Match the following prefixes with the correct values.

a. Mega 1. 1,000 = a,3b. Milli 2. 0.01 = b,4c. Kilo 3. 1.000.000 = c,1d. Micro 4. 0.001 = d,5e. Centi 5. 0.000001 = e,2

Q7.18 Match the following terms with the most appropriate SI units.

a. Tensile strength 1. Kgs/hr = a,4b. Pressure 2. MM/Sec = b,1 x b,4c. Deposition rate 3. Megapascal = c,2d. Wire feed rate 4. Kilopascal = d,2e. Flow rate 5. Ltr/min= e,5

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WELDING METALLURGY FOR THE WELDING INSPECTOR

AWSModule 8

Q8.1 As a metal heated:

a) Energy is added to the structureb) The atoms move further apartc) The atoms vibrate more vigorouslyd) The metal expandse) All of the above

Q8.2 The state of matter, which exhibits the least amount of energy, is:

a) Solidb) Liquidc) Gasd) Quasi-liquide) None of the above

Q8.3 A problem occurring in weldments caused by the nonuniform heating produced by the welding operation is:

a) Porosityb) Incomplete fusionc) Distortiond) Slag inclusionse) None of t he above

Q8.4 which of the following is not a method used to eliminate or reduce residual stresses?

a) Vibratory stress reliefb) External restraintc) Thermal stress reliefd) Peeninge) Annealing

Q8.5 The type of alloying in which the alloy atoms are located in the spaces between the atoms of the parent metal is referred to as:

a) Atomic alloyingb) Substitutional alloyingc) Space alloyingd) Interstitial alloyinge) None of the above

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Q8.6 Rapid quenching of steel from the austenitic range results in a hard, brittle structure known as:

a) Pearliteb) Carbidec) Cementited) Ironitee) Martensite

Q8.7 Very low cooling of steel may result in the production of soft, ductile microstructure which as lamellar appearance when reviewed under high magnification. This structure is referred to as:

a) Martensiteb) Pearlitec) Bainited) Ferritee) Cementite

Q8.8 When rapid cooling produces martensite structure, what sub-critical heat treatment may be applied to improve the ductility of the steel?

a) Quenchingb) Temperingc) Annealingd) Normalizinge) None of the above

Q8.9 It is determined that a welding procedure is creating an excessive heat input. Which of the changes listed below would result in the reduction of heat input?

a) Decrease currentb) Decrease voltagec) Increase travel speedd) Change from weave to stringer bead techniquee) All of the above

Q8.10 The use of preheat will tend to:

a) Result in a wider heat affected zoneb) Produce a lower heat affected zone hardnessc) Slow down the cooling rated) Reduce the tendency to produce martensite in the heat affected zonee) All of the above

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Q8.11 Which of the following changes will warrant an addition or increase in the required preheat?

a) Decreased carbon equivalentb) Increased carbon equivalentc) Increase base metal thicknessd) a and c abovee) b and c above

Q8.12 What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in the furnace?

a) Normalizingb) Quenchingc) Annealingd) Temperinge) Stress relief

Q8.13 What heat treatment characterized by holding the part at austenitizing temperature and then cooling in still air?

a) Normalizingb) Quenchingc) Annealingd) Temperinge) Stress relief

Q8.14 Steel heated above the lower transformation temperature (A1,) will change micro structural alignment. This temperature is?

a) 1333ºFb) 933ºFc) 1560ºFd) 3600ºCe) None of the above

Q8.15 Atom is solid (frozen) state

a) Have a specific “home” positionb) Have no distinct structurec) Are essentially fixed in a definite structured positiond) a and c abovee) None of the above

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Q8.16 What is the heat input for a molten weld pool at 5 ipm travel speed, 25 volts, and 100 amperes? (Amps X Volts X 60 / 100)

a) 300 J/inb) 300,000 J/inc) 30,000 J/ind) 3.633 J/ine) None of the above

Q8.17 One way that atoms are added to a pure metal to from an alloy is:

a) Peeningb) Substitutionallyc) Automaticallyd) Solidificatione) Diffusion

Q8.18 The process where carbon is added to the surface of a steel to harden it is:

a) Decarburizationb) Pack carburizingc) Precipitation hardeningd) Quenching e) None of the above

Q8.19 Steel exists in which of the following crystal structures?

a) BCTb) FCCc) BCCd) All of the abovee) HCP

Q8.20 Which of the following usually follows quenching?

a) Temperingb) Stress relievingc) Normalizingd) Annealinge) None of the above

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Q8.21 Which of the following can be accomplished using either thermal or mechanical techniques?

a) Annealingb) Temperingc) Quenchingd) Stress relievinge) None of the above

Q8.22 Which of the following results in the softest condition for carbon steel?

a) Annealingb) Quenchingc) Stress relievingd) Temperinge) Normalizing

Q8.23 For a steel having a chemistry of: 0.16% carbon, 0.84% manganese, 0.09% nickel, 0.25% chromium, 0.025% copper, and 0.40% molybdenum, what is its Carbon Equivalent?(CE= %C + %Mn/6 + %Ni/15 + %Cr/5 + %Cu/13 + %Mo/4)

a) 0.23b) 0.34c) 0.37d) 0.41e) 0.46

Q8.24 Stainless Steels are defined as having at least what percent chromium?

a) 7%b) 12%c) 15%d) 20%e) 30%

Q8.25 Which of the following methods can reduce Sensitization, or carbide precipitation, of austenitic stainless steels?

a) Solution annealing, water quenchingb) Using stabilized grades containing titanium or niobium (columbium)c) Using the low grades of stainless steelsd) All of the abovee) Using high carbon stainless steels

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Q8.26 Metals must be molten for diffusion to occur.

a) Trueb) False

Q8.27 Hydrogen can diffuse into a solid metal at room temperature.

a) Trueb) False

Q8.28 Metals can dissolve into each other when both are in the solid form.

a) Trueb) False

Q8.29 The process whereby nitrogen is dissolved into the surface of the carbon steel is?

a) Sensitizationb) Nitrogen removalc) Carburizingd) Nitridinge) None of the above

Q8.30 Welding metallurgy is concerned with the changes I the metals during welding

a) Trueb) False

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WELD AND BASE METAL DISCONTINUITIESAWS

Module 9

Q9.1 A discontinuity is:

a) Always a defectb) Always a rejectc) Always acceptabled) Rejectable if it exceeds code limitse) None of the above

Q9.2 The criticality of a weld discontinuity can be judged on the basis of:

a) Whether it is surface or subsurfaceb) Whether is is linear or nonlinearc) Whether it has sharp end conditiond) All of the abovee) Non of the above

Q9.3 What discontinuity is generally considered to be most severe?

a) Porosityb) Incomplete fusionc) Slag inclusiond) Cracke) Arc strike

Q9.4 Which of the following discontinuities is less likely to be seen visually?

a) Toe crackb) Undercutc) Lamellar teard) Overlape) None of the above

Q9.5 Underbead cracks can result from which of the following welding practices?

a) Use of wet electrodesb) Welding o contaminated steelsc) Welding over paintd) Al f the abovee) None of the above

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Q9.6 The weld discontinuity that results form improper termination of the welding arc is referred to as:

a) Undercutb) Overlapc) Crate crackd) Incomplete fusione) All of the above

Q9.7 Of the following processes, which are unlikely to have slag inclusions in a completed, weld?

a) SMAWb) PAWc) FCAWd) SAWe) None of the above

Q9.8 The discontinuity that results from the entrapment of gas within the weld cross section is referred to as:

a) Crackb) Slag inclusionc) Incomplete fusiond) Porositye) None of the above

Q9.9 What weld discontinuity results when the welder travels too slowly, causing excess weld metal to flow out of the joint and lay on the base metal surface without fusing?

a) Undercutb) Underfillc) Overlapd) Incomplete fusione) None of the above

Q9.10 What weld metal discontinuity results when the welder fails to completely fill the weld groove?

a) Underfillb) Undercutc) Overlapd) Incomplete fusione) None of the above

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Q9.11 Excessive weld metal buildup on a groove weld is referred to as:

a) Excessive convexityb) Excess weld reinforcementc) Overfilld) All of the abovee) None of the above

Q9-12 The weld discontinuity that results from the initiation of the welding are outside the weld joint is referred to as:

a) Incomplete fusionb) Undercutc) Overlapd) Scratch starte) Are strike

Q9-13 What weld discontinuity shows up as a light region on a radiograph?

a) Porosityb) Tungsten inclusionc) Slag inclusiond) A and b abovee) B and c above

Q9-14 Which of the following is not a base metal discontinuity, resulting from improper steel making practices?

a) Lamination b) Lamellar tearc) Seamd) Pipe shrinkagee) None of the above

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VISUAL INSPECTION, OTHER NDE METHODS AND EXAMINATION SYMBOLS

AWSModule 10

Q10.1 Which of the following Nondestructive testing methods are limited to the detection of surface discontinuities?

a) Visualb) Penetrantc) Radiographicd) A and b abovee) B and c above

Q10.2 To be most effective visual inspection should be performed when?

a) Before weldingb) During weldingc) After weldingd) All of the abovee) None of the above

Q10.3 The time period during which the penetrant remains on the surface of the part allowing it to be drawn into any surface discontinuities is called what?

a) Waiting timeb) Penetrating timec) Soak timed) Dwell timee) None of the above

Q10.4 Which type of magnetizing current provides the best iron particle mobility?

a) ACb) DCc) DCEPd) B and c abovee) All of the above

Q10.5 What MT technique could be used for the discovery of longitudinal flaws

a) Head shot (circular magnetism)b) Side shotc) Coil shot (longitudinal magnetization)d) A and b abovee) B and c above

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Q10.6 Which of the following magnetizing methods produce a circular magnetic field in the test piece?

a) Head shotb) Passing an electrical current through the partc) Prodd) All of the abovee) None of the above

Q10.7 Which of the following magnetizing methods can produce a longitudinal filed in the test piece?

a) Head shotb) Coil shotc) Yoked) A and b abovee) B and c above

Q10.8 What NDT methods are best for evaluating subsurface porosity?

a) PTb) MTc) RTd) VTe) All of the above

Q10.9 Which of the following statement is correct for radiographic testing?

a) A reduction in thickness will produce a lighter image on the filmb) A low density discontinuity will produce a lighter image o the filmc) A high density discontinuity will produce a lighter image on the filmd) A and b abovee) B and c above

Q10.10Radiographic testing (RT) can be performed using which of the following?

a) X-ray machineb) Cesium 137c) Iridium 192d) Cobalt 60e) All of the above

Q10.11MT can be used most effectively to inspect which of the following?

a) Austenitic stainless steel welds on carbon steelb) Austenitic stainless steel welds on stainless steel c) Carbon steel welds on carbon steel

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Q10.12Which of the following discontinuities will not usually be revealed using RT?

a) Crackb) Incomplete joint penetrationc) Porosityd) Laminatione) None of the above

Q10.13What is used during radiography to indicate the resolution sensitivity of a radiograph?

a) IQIb) Dosimeterc) Lead screend) All of the abovee) None of the above

Q10.14Which Nondestructive test method uses sound energy as a probing medium?

a) MTb) RTc) UTd) PTe) ET

Q10.15The process whereby ultrasonic indications are related to dimensions in a test standard is referred to as?

a) Setupb) Calibrationc) Standardizationd) Synchronizatione) None of the above

Q10.16As-welded groove welds are usually inspected ultrasonically using what technique?

a) Straight beamb) Shear wavec) Angle beamd) A and c abovee) All of the above

Q10.17Capillary action plays a role in which NT method?

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a) ETb) UTc) RTd) PTe) MT

Q10.18Which NDT method is considered to be a true volumetric test?

a) RTb) UTc) PTd) MTe) ET

Q10.19Which NDT method uses an alternating current coil?

a) MTb) UTc) ETd) A and c abovee) B and c above

Q10.20Changes in heat treatment can be measured using which NDT method?

a) ETb) RTc) MTd) UTe) None of the above

Q10.21Which of the following NDT methods can detect surface cracks?

a) RTb) VTc) ETd) PTe) All of the above

Q10.22Which NDT method is most likely to reveal subsurface laminations in a rolled plate?

a) RTb) UTc) ETd) MT

Q10.23Piezoelectricity is a property used by which NDT method?

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a) ETb) UTc) RTd) A and b above

Q10.24Which is the best technique for orienting magnetic lines of force when conducting MT testing?

a) Two directionsb) Single directionc) Residual magnetismd) All of the abovee) None of the above

Q10.25What resolution sensitivity is normally required for RT?

a) 2%b) 4%c) 5%d) 7%e) 9%

Q10.26What is the basic element of evaluation in any quality control program?

a) Radiographic testingb) Penetrant testingc) Visual inspectiond) All of the abovee) None of the above

Q10.27When should the applicable job documents be reviewed?

a) After the job completedb) Before the welding beginsc) At any time when information s neededd) A and b abovee) B and c above

Q10.28What is the role of the AWS CWI in NDE?

a) See that inspections are doneb) Verify personnel qualifications for NDE inspectionc) Prepare proper recordsd) See that proper records are maintainede) All of the above

Q10.29A number in parentheses just above or below a test symbol describes:

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a) The length of weld to be testedb) The extent of testingc) The number of tests to performd) The type of test to performe) None of the above

Q10.30A number to the right of a nondestructive testing symbol refers to the:

a) Number of test to performb) The length of weld to be testedc) The applicable quality standardd) The test procedure to usee) None of the above

Q10.31Test information above the reference line refers to the arrow side:

a) Trueb) False

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