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1. A crack running along the centreline of a weld bead could be caused by:
Use of damp flux
A.
Lack of preheat
B.
Arc voltage too high
C.
Weld bead too deep and very narrow
D.
2. When welding thin plate distortion can be minimised by:
Welding from both sides
A.
Using U preparations rather than V types
B.
Using strongbacks
C.
Using back-step welding
D.
3. EN ISO 5817 (Level C) specifies that the limit for the diameter (D) of a single pore in a
weld is: D<0.3s, but max. 4mm where s=material thickness. For which of the following
situations is the pore acceptable?
s=20mm, measured pore diameter = 5mm
A.
s=15mm, measured pore diameter = 4.5mm
B.
s=10mm, measured pore diameter = 3mm
C.
s=10mm, measured pore diameter = 3.5mm
D.
4. Typical temperature used for normalising a C-Mn steel plate are:
600-650C
A.
1000-1100C
B.
700-800C
C.
880-920C
D.
5. The use of low carbon austenitic stainless steels and stabiliser stainless steels will minimise
the risk of:
HAZ cracking
A.
Weld decay
B.
Weld metal cracking
C.
Distortion
D.
6. Transfer of material identification by hard stamping is sometimes not allowed for high
integrity applications because it:
Is too slow
A.
Can be a safety hazard
B.
May damage the material
C.
Causes problems with coating operations.
D.
7. Which of the following is associated with SAW more often than it is with MMA welds?
Hydrogen cracking in the HAZ
A.
Solidification cracking in the weld metal
B.
Reheat cracking during PWHT
C.
Lamellar tearing
D.
8. A C-Mn steel is being welded by MMA and the electrode run-out lengths that have been
used are much shorter than specified by the WPS. This deviation may give:
Increased risk of hydrogen cracking
A.
Increased risk of solidification cracking
B.
Lower values of HAZ toughness
C.
Higher values of HAZ hardness
D.
9. Which of the following is a suitable shielding gas for FCAW of stainless steels?
100% Argon
A.
70% Argon + 30% He
B.
Argon + 5% Hydrogen
C.
Argon + 20% CO2
D.
10. Which of the following would be considered to be high heat input welding?
550J/mm
A.
55J/mm
B.
5.5J/mm
C.
5KJ/mm
D.
11. Initiation of a TIG arc using high frequency spark may not be allowed because it:
Often causes tungsten inclusions
A.
Can damage electronic equipment
B.
Is an electrical safety hazard
C.
Often causes stop/start porosity
D.
12. A Large grain size in the HAZ of a C-Mn Steel weld joint may have:
Low ductility
A.
Low toughness
B.
High toughness
C.
High tensile strength
D.
13. Lamellar tearing has occurred in a steel fabrication. What technique could have been used
to find it before the weld was made?
X-ray examination
A.
Liquid penetrant examination
B.
Ultrasonic examination
C.
It could not have been found by any inspection method
D.
14. The presence of iron sulphides in a weld bead may cause:
Solidification cracking
A.
Hydrogen
cracking
B.
Lamellar tearing
C.
Weld decay
D.
15. Which type of SAW flux is susceptible to breaking down into fine particles during
circulation?
Fused
A.
Neutral
B.
Alloyed
C.
Agglomerated
D.
16. For MMA welding of a 60mm wall nozzle to a 100mm wall vessel shell, preheat
temperatures should be checked:
Before welding starts/restarts
A.
On the shell and nozzle
B.
At points at least 75mm from the joint edge
C.
All of the above
D.
17. Preheating a low alloy steel prior to welding to minimise the risk of:
Porosity
A.
B.
C.
D.
Excessive distortion
HAZ cracking
Lack of fusion
26. The first procedure prepared for a Weld Procedure Qualification test is a:
pWPS
A.
WPS
B.
WPQR
C.
WPAR
D.
27. A macrosection is particularly good for showing:
The weld metal HAZ microstructure
A.
Overlap
B.
Joint hardness
C.
Spatter
D.
28. For GMAW the burn-off rate of the wire is directly related to:
Stick-out length
A.
Wire feed speed
B.
Arc voltage
C.
Travel speed
D.
29. Which type of submerged arc welding flux is susceptible to moisture pick-up?
Neutral
A.
Agglomerated
B.
Fused
C.
Are all about the same
D.
30. To measure arc voltage accurately it is recommended that the voltmeter should be
connected:
Across the arc and as near as practical to the arc
A.
Across the power source terminals prior to arc initiation
B.
Across the power source terminals during the welding operation
C.
Anywhere in the circuit
D.
Question Excerpt
1. Welds made with very high heat input will show a reduction in:
Tensile ductility
A.
Notch toughness
B.
Fatigue strength
C.
Creep resistance
D.
2. Carbon equivalent values (CEV) are used to determine how to avoid the risk of:
Hydrogen cracking
A.
Lamellar tearing
B.
Solidification cracking
C.
weld decay
D.
3. Changing an essential variable beyond the allowed limits for a qualified welding
procedure:
May change the mechanical properties of the joint
A.
May adversely affect the quality of the weld
B.
Will require a new welding procedure to be approved
C.
All of the above
D.
4. When MAG welding in dip transfer (a short-circuiting mode) spatter can be reduced by:
Using inductance
A.
Using 100%CO2
B.
Using Ar +30% He
C.
Increasing the stick-out length
D.
5. A transverse tensile test from a Weld Procedure Approval Record (WPAR) test plate is
used to measure:
Tensile strength of the weld
A.
Tensile strength of the joint
B.
Stress/strain characteristics of the weld
C.
Stress/strain characteristics of the joint
D.
6. The highest and lowest heat input positions are considered to be:
PB highest; PA lowest.
A.
PE highest; PC lowest.
B.
PD highest; PB lowest.
C.
PF highest; PG lowest.
D.
7. Which of the following AWS A5.1 electrodes has a rutile covering:
E 6010
A.
E 7016
B.
E 7018
C.
E 6013
D.
8. What determines the penetrating power of gammer rays?
Time
A.
Type of isotope
B.
Source-to-film-distance
C.
Source strength
D.
9. Which element has the greatest effect on the HAZ hardness of C-Mn steel?
Molybdenum
A.
Chromium
B.
Titanium
C.
Carbon
D.
10. BS EN 288 and BS EN ISO 15614 are specifications for?
Welder approval testing
A.
Welding
equipment calibration
B.
Welding procedure approval
C.
Consumables for submerged arc welding
D.
11. For SAW, what is the effect of raising arc voltage but keeping all other parameters the
same?
Weld bead width will increase
A.
Depth of penetration will increase
B.
Weld bead width will decrease
C.
Depth of penetration will decrease
D.
12. A penertrameter (IQI) is used to measure the:
Size of discontinuity in a weld joint
A.
Density of a radiographic film
B.
C.
D.
13. What type of covering will an electrode have that is suitable for welding 60mm C-Mn
steel and can give good weld metal toughness at -50C?
Rutile
A.
Basic
B.
Cellulosic
C.
Choice will depend on the welding position
D.
14. A welder approval certificate should be withdrawn if:
He has not done any welding for 4 months
A.
He has been absent from work for 7 months
B.
The repair rate for his work exceeds 1%
C.
His work has been examined by UT only
D.
15. Preheating a steel plate with a carbon equivalent (CEV) of 0.48 may be required to:
Drive moisture from the plate
A.
Prevent excessive hardening in the HAZ
B.
Prevent the formation of carbides
C.
Improve the mechanical properties of the weld metal
D.
16. The sensitivity of a radiograph is assessed:
By using a densitometer
A.
By using an image quality indicator (IQI)
B.
From the KVA used
C.
From the source/tube to work standoff distance used
D.
17. The dip transfer or short-circuiting mode of metal transfer used for MIG/MAG welding is
characterized by:
Giving deep penetration
A.
Being suitable for positional welding
B.
Giving low spatter
C.
Giving high deposition
D.
18. Which of the following cutting methods is suitable for cutting stainless steel?
Plasma
A.
Oxy-acetylene
B.
Oxy-propane
C.
It depends upon the thickness.
D.
19. Which of the following would be classed as the most serious type of defect?
A buried linear slag inclusion
A.
Buried lack of inter-run fusion
B.
Surface breaking lack of sidewall fusion
C.
Surface porosity
D.
20. Exceeding the maximum interpass temperature specified for a C-Mn steel weld joint may
give:
Excessive porosity
A.
Burn through
B.
Lower toughness
C.
Higher strength
D.
21. With reference to the various grades of stainless steels which of the following statements
is true?
They are all non-magnetic
A.
They all require 100% Ar for GMAW
B.
They all have very high thermal conductivity
C.
Only certain grades can be used for service at very low temperatures
D.
22. In friction welding, the metal at the interface when the joining occurs is describes as
being in the:
Liquid state
A.
Intercritical state
B.
Plastic state
C.
Elastic state
D.
23. The temperature range over which a steel goes from having high to low toughness is
called the:
Critical transformation temperature
A.
Ductility dip temperature
B.
Bi-modal temperature
C.
Transition temperature
D.
24. MIG/MAG welding has a tendency to give lack of sidewall fusion when:
Spray transfer conditions are used
A.
100% CO2 shielding gas is used
B.
Pulsed current is used
C.
Dip transfer
D.
25. When two different material types are welded together the joint is referred to as:
A composite joint
A.
A transition joint
B.
An autogenous weld
C.
Heterogeneous joint
D.
26. During PWHT of a complex fabrication, it is heated to the soak temperature at a much
faster rate than specified by the procedure. This may:
Cause excessive oxidation
A.
Not allow sufficient time to relieve stresses
B.
Introduce excessive compressive stresses
C.
Cause distortion
D.
27. Repair welding of in-service plant and equipment may be more difficult than making
repairs during initial fabrication because:
The material may be contaminated
A.
Access to repair area may be difficult
B.
Positional welding may be needed
C.
All of the above
D.
28. Which of these drawing symbols shows weld penetration depth in accordance with BS
EN 22553?
A.
B.
C.
D.
29. For gammer radiography of a steel weld at 35mm thickness, the recommended isotope is:
Thulium 170
A.
Ytterbium 169
B.
Iridium 192
C.
Cobalt 60
D.
30. Ultrasonic testing has an advantage over other NDT methods for the detection of:
Lack of sidewall fusion
A.
Root undercut
B.
Incompletely filled groove
C.
Root concavity
D.