Professional Documents
Culture Documents
1. When H2 control is specified for a manual metal arc welding project, the
electrode would normally be:
1. Cellulose
2. Iron oxide
3. Acid
4. Basic
1. Color
2. Length
3. Trade Name
4. AWS / BS639 Code Letter
4. You notice manual metal arc electrodes, stripped of flux, are being used as
filler wire for TIG welding. You would object because:
1. It is too expensive
2. The wire would be too thick
3. The weld metal composition may be wrong
4. The wire is too short
5. When open site working, serious porosity in metal arc welds is brought to
your attention. What would you investigate:
1. Electrode type
2. Power plant type
3. Electrode storage
4. Day temperature
1. Porosity
2. Cracking in the weld area
3. Undercut for fillet welds
4. Lack of root fusion defects
1. 4% Chromium Molybdenum
2. 12% Chromium
3. Austenitic Stainless Steel
4. 9% Nickle Steel
8. When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is
called for. This is to:
1. Prevent oxidation
2. Prevent under bead cracking
3. Prevent porosity
4. Control the penetration bead shape
1. Scattered porosity
2. Worm hole porosity
3. Parent metal cracking
4. Lack of penetration
10. In UK practice, BS499 part 2 specifies that the drawing dimension quoted
for a fillet weld is the:
1. Leg length
2. Actual throat thickness
3. Weld length
11. For open site manual metal arc welding the following equipment is
available. Which would you choose for safe working?
12. If Submerged arc welding is to be used to make butt welds, which would
you be most critical of?
13. During CO2 welding, the arc length is most likely to be affected by:
15. You see a welder using an oxy-acetylene flame with a long feathered inner
cone. What would be the effect of this on a carbon steel?
1. H A Z cracking
2. Fatigue life
3. Residual stress
4. Yield strength
18. Bend test specimens have been taken from a 25mm thick carbon steel butt
weld. Which would show lack of inter-run fusion:
1. Side bend
2. Root bend
3. Face bend
4. Guided bend
19. Lamellar tearing has occurred in a steel fabrication. Before welding could it
have been found by:
1. X-ray examination
2. Dye penetrant
3. Ultrasonic inspection
4. It would not have been found by any inspection method
20. You are to oversee the arc welding of some machined fittings and find they
are cadmium plated. Would you:
1. Permit it to proceed
2. Permit it to proceed with fume extraction
3. Stop the operation at once
4. Advise the welder to drink milk and proceed
21. The unit of Joules would be used to measure:
1. Tensile strength
2. Impact energy
3. Hardness
4. Electrical resistance
1. E 6010
2. E 7018
3. Sub are flux with Basicity Index of 2
4. Sub are flux with Basicity Index of 3
1. When the run out date of the procedure has been reached
2. Every Year
3. When changing from day to night shift work
4. When there is a change in an essential variable
1. Hydrogen cracks
2. Laps and laminations
3. Center line cracks
4. Porosity
27. To prevent the hardening and cracking of High Carbon Steel plate when
flame cutting it is advisable to:
1. Softer
2. Harder
3. Tougher
4. Stronger
29. You should always refer to a higher authority for guidance when:
30. Spatter may be finely controlled during MIG / MAG welding by:
33. In BS 639 and BSEn 499 the first digits of the electrode classification
indicate:
37. On which of the following would you not use MPI inspection?
39. In Sub Arc Welding, excessive flux melting will result from:
40. To BS 499 part 2, which of the following is true for a welding symbol:
1. This or arrow side of the joint goes on top of the reference line
2. This or arrow side of the joint goes below the reference line
3. This or arrow side of the joint goes in the middle of the reference
line
4. All of the above
1. Penetrant testing
2. Impact tests
3. Side bend test
4. Hardness test
42. Which of the following steel structures has the highest hardness:
1. Martensite
2. Austenitic
3. Ferritic
4. All have the same hardness
1. Image quality
2. Type of steel
3. Density of graph
4. Type of welding process used
44. Poor penetration would be found in MIG / MAG welded steels when using:
45. In which of the following steels are you most likely to find H2 induced
weld metal cracking after welding:
1. A slipping agent
2. A slag former
3. A de-oxidant
4. A colouring agent
47. The main reason degreasing agents should always be dried from metals
prior to welding, is because they are likely to:
48. Which of the following processes would be most prone to lack of fusion
defects:
1. Argon
2. Xenon
3. Carbon dioxide
4. Helium
1. SAW
2. TIG
3. MIG / MAG
4. MMA
1. Is repairable
2. Always results in a cut out and complete re-weld
3. Is acceptable up to 2mm in length
4. May be repaired or cut out depending on specification requirements
57. If the amperage is too low during the welding of a root bead, the possible
result would be:
1. Lack of penetration
2. Lack of fusion
3. The freezing of the electrode
4. All of the above
1. Lack of fusion
2. Low amperage
3. Undercut
4. Hydrogen cracking
1. It becomes malleable
2. Its hardness increases
3. It becomes ductile
4. The plasticity is increased
1. Cellulosic
2. Non consumable
3. Consumable
4. None of the above
1. Concavity
2. Convexity
3. LORP
4. Root undercut
65. The extent of the changes in microstructure will depend on the following:
1. Material composition
2. Heat input
3. The rate of cooling
4. All of the above
1. BS 4872
2. BS 499
3. BS 4870
4. None of the above
67. A code of practice for visual inspection should cover the following:
1. Linear misalignment
2. Incorrect tilt angle
3. Differing root face widths
4. All of the above
70. You notice a very yeed ripple shape. This is most likely caused by:
1. Toughness
2. Fatigue life
3. Penetration
4. All of the above
1. Excessive amps
2. Excessive volts
3. Excessive travel speed
4. All of the above
1. Up to 50
2. 2 2.5
3. 50 100
4. None of the above
78. When visually inspecting a fillet weld, it would normally be Sized by:
81. Defects outside of the limits specified in a standard should always be:
1. Repaired
2. Reported to a senior person
3. Radio graphed
4. All of the above
1. Poor access
2. Loss of gas shield
3. Dirty materials
4. All of the above
1. Solidification problems
2. Hydrogen problems
3. Excessive stresses
4. All of the above
86. Welding a single V butt with laminations showing on the side wall may
give rise to:
1. Lamellar tearing
2. Solidification cracking
3. Martensite
4. Undercut
87. With reference to a root penetration bead, you could certainly assess:
1. Root fusion and penetration
2. Root concavity
3. Burn through
4. All of the above
91. Flame cut preparation may, during welding, increase the likelihood of:
1. Cracking
2. Misalignment problems
3. Inclusions
4. All of the above
1. Slag inclusions
2. Fusion defects (Inter run)
3. Fusion defects (Surface)
4. Porosity
1. Arc deviation
2. Arc misalignment
3. Arc blow
4. Arc eye
96. A metallurgical problem most associated with Submerged Arc welding is:
97. Oxy pressure and nozzle size would influence what in flame cutting:
1. Friction welding
2. Resistance welding
3. Plasma welding
4. All of the above
1. E 6013
2. E 5133
3. E 7018
4. Fleet weld 5
1. Rutile
2. Cellulosic
3. Basic
4. Oxidizing
1. 100 % CO2
2. 100% Argon
3. 80% Argon 20% CO2
4. 98% Argon 2% Oxygen
1. Fused
2. Agglomerated
3. Basic
4. All of the above the same resistance
104. The flame temperature of oxy / acetylene mixture gas is given as:
1. 3200* C
2. 2300* C
3. 5000*C
4. None of the above
105. A large grain structure in steels said to produce:
107. Repair welding is often more difficult than production due to:
111. In a bend test, the face of the specimen is in tension and root is in
compression, the type of test being carried out would be:
1. Annealing
2. Normalising
3. Hardening
4. Stress relieving
114. The presence of iron sulphide in the weld metal is most likely to
produce which of the following upon contraction of the weld:
1. Solidification cracking
2. Hydrogen cracking
3. Intergranular corrosion
4. Stress corrosion cracking
115. When visually inspecting a completed single V butt cap you would
certainly assess:
1. Cap height
2. Toe blend
3. Weld width
4. A, B & C
116. Generally the most suitable method of detecting lack of side wall
fusion would be:
1. UT
2. MPI
3. RT
4. PT
1. Lamellar tearing
2. Solidification cracking
3. Hydrogen cracking
4. None of the above
1. Thin material
2. Tee joints
3. Plate thickness greater than 25mm
4. None of the above
1. A bevel butt
2. A J butt
3. A K butt
4. All of the above
1. -
2. -
3. -
4. -
1. A standard
2. A Set of rules for the manufacture of a product
3. Related to welder and weld procedure approval
4. All of the above
1. Reinforcement
2. Cap profile height
3. Excess weld metal
4. All of the above
1. Weld decay
2. Sensitisation
3. Solidification cracking
4. All of the above
1. Weldability aspects
2. Crack sensitivity aspects
3. Typical mechanical properties
4. All of the above
131. When referring to TIG welding, the shielding gas could be:
1. Argon + Hydrogen
2. Argon + Helium
3. Argon + Nitrogen
4. All of the above
132. When referring to MIG welding, the shielding gas could be:
1. Argon
2. Argon + 1% oxygen
3. Argon + 20% CO2
4. None of the above
1. Planar
2. Cracks
3. Lack of fusion
4. All of the above
1. Fatigue crack
2. Stress corrosion crack
3. Porosity
4. Lack of penetration
1. Fatigue crack
2. Porosity
3. Machining tear
4. Lap
1. Acid
2. Water
3. Salts
4. All of the above
139. Which of the following is a discontinuity that might be found in a
forging?
1. Shrinkage cracks
2. Laps
3. Cold shuts
4. Insufficient penetration
140. The prime purpose of the black light for fluorescent penetrant
inspection:
1. To magnify indications
2. To make the indications visible
3. To develop indications
4. To speed up inspection
1. > 15 ml
2. > 15 ml < 25 ml
3. > 10 ml < 15 ml
4. > 5 ml < 10 ml
142. Which is the correct heat input if the amps are 350, volts 32 and
travel speed 310 mm / s?
1. 2.16 kJ / mm
2. 0.036 kJ / mm
3. 2160 kJ / mm
4. 36 kJ / mm
143. In accordance with BS 5135 what is the minimum distance the pre
heat shall be applied from the joint preparation?
1. 100 mm
2. 25 mm
3. 75 mm
4. Not specified
1. A 17 wire
2. A 18 wire
3. A 15 wire
4. All of the above
1. BS EN 499
2. BS 639
3. AWS A5.5
4. AWS A5.1
150. Which of the following is most likely to reduce the chances of arc
blow?
1. A change from ac current to dc current
2. A change from dc current to ac current
3. A change from dc electrode +ve to de electrode ve
4. A change from dc electrode ve to dc electrode +ve
152. When welding a double V butt joint with SAW process the presence
of centerline porosity may be due to:
1. Damp flux
2. Contaminated joint preparation
3. Incorrect stick out lengths
4. All of the above
155. The HAZ associated with a fusion weld on steel has up to how
many separate regions of micro structure?
1. 4
2. 6
3. 1
4. 2
1. Joint set up, flux coating, polarity, travel speed and amps / volts
2. Amps / volts, WFS, gas flow rate, polarity and travel speed
3. Amps / volts, WFS, wire diameter, polarity and travel speed
4. Electrode stick out, WFS, amps / volts, polarity and wire diameter
158. Which of the following statements is true when using a flat
characteristic power source?
159. Which of the following will vary the most, when varying the arc
length?
1. Voltage
2. Amperage
3. Polarity
4. None of the above
1. The core wire in a MMA electrode has a higher melting point than
the flux
2. Electrode dc +ve is used when welding with the MIG / MAG
welding process
3. The HAZ of a carbon manganese steel weld usually has a lower
ultimate tensile strength than the weld
4. All of the above are true
161. A multi run MMA butt weld made on C/Mn steel consists of 5
passes using 6mm electrodes. A 12 pass weld made on the same joint using
4mm electrodes on the same material will:
162. The main reason for using a back purge when welding 18-8 stainless
steel with the TIG welding process is to:
164. Which is often the hardest part of a multi run weld made using
MMA?
166. Which of the following welding processes would you expect to use
a collet:
1. TIG / TAG
2. MIG / MAG
3. MMA
4. All of the above
167. Which of the following may be used for the TIG / TAG welding of
austenitic stainless steel?
1. Lathanum electrode dc ve
2. Cerium electrode dc ve
3. Zirconium electrode ac
4. Thorium electrode dc ve
1. BS 639
2. BS 2901
3. BS 2633
4. BS 4165
170. What are the possible results of having a too lower heat input?
1. Killed steel
2. Rimming steel
3. Carbon steel
1.
2.
3.
173. Which of the following NDT method is not suitable to detect sub
surface defect?
1. UT
2. PT
3. RT
4. MPI
175. In SAW process if voltage and current is increased and travel speed
is decreased, what will be the effect in the profile?
1. Wider weld
2. Higher weld reinforcement
3. Concave weld surface
176. What change will occur on the HAZ during heating of metal caused
by welding?
1. Basic
2. Rutile
3. Cellulosic
1. Slag inclusions
2. Hydrogen cracking
3. Lack of side wall fusion
4. Porosity
179. Which of the following mechanical properties of a weld in carbon
manganese steel is not affected if the heat per unit length of weld is
excessively high?
1. Elongation
2. Tensile strength
3. Hardness
4. Toughness
180. You observe centerline cracking in a weld that has been made at one
of five work station each making similar components. The first action to
take is:
1. Linear misalignment
2. Undercut
3. Overlap
4. Linear slag inclusions
1. MMA
2. SAW
3. Electro slag welding
4. Resistance spot welding
1. Arc voltage
2. Current
3. Wire / Electrode feed rate
4. Metal burn off rate
1. Voltage
2. Welding speed
3. Iron powder in the coasting
4. Current
185. In the welding of a butt joint made from one side, which of the
following controls the profile of the root bead?
1. Root face
2. Bevel angle
3. Root gap
4. None of the above
1. Constant voltage
2. Flat characteristic
3. Drooping Characteristic
4. Motor generator
1. Macro
2. Nick break
3. Hardness
4. Charpy vee notch
188. Degreasing components are essential for quality welding but some
agents may:
189. Which of the following chemical elements has the greater effect on
the hardenability of a steel plate?
1. Molybdenum
2. Chromium
3. Titanium
4. Carbon
190. In MIG ? CO2 welding which parameters give the greatest control
of weld appearance during dip transfer or short circuiting welding?
1. Fluid
2. Viscous
3. None of the above
4. Semi fluid
192. The weld metal deposit of MMA electrodes, achieves its mechanical
strength through:
1. Iron powders
2. Calcium fluoride
3. Silicon
4. Calcium carbonate
194. Welds made with high heat inputs show a reduction in one of the
following properties:
1. Ductility
2. Toughness
3. Fatigue strength
4. Mechanical strength
195. In X-ray the quality of radiographic negative is assessed by the:
197. Which one of the following type of steels would give rise to the
formation of porosity when autogenously welded with an arc process?
198. In SAW, the use of excessively high voltage would result in:
199. The use of cellulosic electrodes is often made when welding the root
pass of pipes in the field. This is because:
1. H2 control is needed
2. Iron powders in the electrode
3. Higher arc voltage can be obtained
4. Shorter arc length can be achieved
200. In the welding of austenitic stainless steels, the electrode and the
plate material can be purchased with low carbon contents. The reason for
this is to prevent:
201. Submerged arc fluxes can be supplied in two forms. These are:
1. Tungsten
2. Manganese
3. Molybdenum
4. Carbon
204. Which one of the following processes uses the Key holing system
of fusion?
1. Friction welding
2. Diffusion welding
3. Electron beam welding
4. Autogenous TIG welding
1. Liquid state
2. Solid state
3. Plastic state
4. Elastic state
207. BS 499 part II communicates by the use of symbols the type of joint
preparation to be used. Listed below are four symbols. Which of these
indicates the depth of penetration of the weld required on the joint?
1.
2.
3.
4.
208. In accordance with BS 499 what is the weld junction?
209. Which of the following are essential factors for lamellar tearing?
1. The flame is described towards the welded part and filler material is
directed toward un-welded part of the joint
2. The flame and filler material both directed towards welded part of
the joint
3. The flame is directed towards the un-welded part and filler material
is directed towards welded part of the joint
4. The flame and filler material is both directed towards un-welded
part of the joint
1. Heating rate
2. Temperature attained
3. Cooling rate
4. All of the above
214. Most metals expand when heated, the change in length is expressed
as:
1. Thermal conductivity
2. Modulus of elasticity
3. Coefficient
4. Yielding
1. Copper
2. Aluminum
3. Ceramic
4. Copper / Zinc
1. Neon
2. Xenon
3. Argon
4. Nitrogen
1. Short electrode length, the control of the arc length and the process
uses a flat characteristic
2. Short electrode length, the control of the arc length and flux
coverings
3. The control of the arc length, stop start problems and short electrode
length
4. Flux coverings, short electrode lengths and relationship between
amps and volts
1. The welder is responsible for the arc gap and travel speed
2. The welder is responsible for the travel speed only
3. The welding plant controls both travel speed and arc gap but under
constant supervision
4. The welding plant controls both travel speed and arc gap, no
supervision required
1. A proton
2. A photon
3. An electron
4. A neutron
225. Three essential factors for producing fusion weld are melting,
removal of surface oxide from the joint surfaces and elimination of
atmosphere from the region of the arc. Name the fourth one:
1. MMA PG position
2. Mechanised arc welding
3. Sub Arc
4. All of the above
5. None of the above
228. Name the fourth weld process crack which has a totally different
formation mechanism to HICC (H2 induced cold crack), solidification
cracking and lamellar tearing:
1. Liquation cracking
2. Reheat cracking
3. Crater cracking
4. Hot tearing
232. Which of the following in a fusion weld usually has the highest
tensile strength?
1. Weld metal
2. Parent material
3. HAZ
4. Fusion zone
1. Cold crack
2. Tearing
3. Star crack
4. Fatigue crack
234. What action must the welding inspector request if a lamination is
found extending into the bevel face?
235. The deviation of the arc during arc welding due to external magnetic
influences is known as:
1. Arc strike
2. Arc blow
3. Paramagnetic interference
4. Diamagnetic interference
237. Which of the following heat treatment processes would be used for
grain refinement?
1. Annealing
2. Normalizing
3. Quenching
4. H2 release
238. A repair has been made using MMA on a double V butt weld on a
10 m diameter tank. The defect repaired was lack of inter-penetration and it
had been excavated with a disc grinder prior to repair. After repair it was
determined that the wrong electrodes had been used. What action should
the inspector take:
240. What is the possible cause of too mush restraint of the parent
material during welding?
1. Argon
2. Neon
3. Carbon dioxide
4. Helium
1. MIG
2. TIG
3. SAW
4. None of the above
247. Which of the following current types would be used for welding
aluminum with the TIG welding process?
1. Ac
2. Dc +ve electrode
3. Dc ve electrode
4. All of the above could be used successfully
1. 1
2. 2
3. 3
4. As many as possible
1. Is hig for a C-Mn steel and may require a preheat temperature over
100*c
2. Is insignificant for a C-Mn steel and preheat will not be required
3. Is calculated from the heat input formula
4. Is not a consideration for determining preheat temperature
1. Fissure
2. Lamellar tear
3. Fish eye
4. Reheat crack
1. TIG
2. MIG
3. MAG
4. All of the above
1. BS EN 25817
2. BS EN 26520
3. BS EN 22553
4. BS EN 24165
1. Cold shortness
2. Hot shortness
3. An increase in ductility
4. An increase in malleability
1. Perlite
2. Martensite
3. Bainite
4. All of the above are undesirable grain structures in constructional
steels
1. Divide by 144.9
2. Multify by 25.4
3. Divide by 14.7
4. Multify by 14.7
1. 144.9
2. 25.4
3. 14.7
4. 1.
262. What is the UTS of a material?
1. Cellulosic
2. Titanium dioxide
3. Calcium carbonate
4. Asbestos
1. Basic
2. Cellulosic
3. Rutitle
4. None of the abobe
1. To carry out inspection and NDT in order to find all weld flaws
present
2. To attempt to ensure that all welding and any associated actions are
carried out in accordance with agreed specification
3. To carry out welding inspection and radiography interpretation with
agreed procedure for the work being undertaken
4. To make sure that all the welds are defect free
273. Which of the following butt weld preparation is usually the most
susceptible to lack of side wall fusion during MMA welding?
275. What is the throat thickness of a mitre fillet weld equal leg length?
276. Which of the following will vary the most when varying the arc
length using the MMA process?
1. Voltage
2. Amperage
3. Polarity
4. None of the above
277. What is a possible result if the amperage is too low during the
welding of a root bead using an arc welding process with a consumable
electrode?
1. Concave root
2. Elongated porosity in the root
3. Lack of penetration
4. A slag line above the root pass
289. Which of the following sentences applies to the use of basic MMA
electrodes?
1. They are used to deposit weld metal in the vertical position only
2. They are used where deep penetration is a primary requirement
3. They are usually used to deposit weld metal of low hydrogen
content
4. Basic electrodes are chosen when ease of use is of importance
1. SAW
2. MMA
3. TIG
4. ESW
292. The hardest grain structure capable of being produced when welding
C/Mn steel is:
1. Bainite
2. Austenite
3. Pearlite
4. Martensite
293. The presence of too much hydrogen when welding C/Mn steels
would be to cause the formation of:
1. Porosity
2. Lack of fusion
3. Crack
4. undercut
295. Why is stress relief (PWHT) some times carried out on weldments?
296. When welding a double V butt with the SAW process the presence
of center line porosity may be due to:
1. Damp flux
2. Incomplete penetration
3. Contaminated weld preparation
4. Atmospheric contamination
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