Practice Examination and Sample Questions for Visual Inspection Workshop

v. June 2008

VIW PRACTICE EXAMINATION

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Refer to Part B Specification in the VIW Manual

Read each question carefully and select the one best answer. It is helpful for you to write down the Appendix number(s) and page(s) where you find the answer. The exam should be completed within a two hour period. 1. The designer is specifying the joint designation, B-U2-GF, for the welding of two structural members. What is the maximum acceptable range of root opening dimensions, as detailed, available to the designer for that joint configuration? a. 0 to 1/8 inch b. 1/16 inch to 3/16 inch c. 0 to 1/4 inch d. 0 to 3/16 inch e. none of the above 2. Where should the designation A5.18 be placed on the Appendix I form? a. space # 5 b. space # 6 c. space # 7 d. space # 1 e. none of the above 3. Which of the following would be a matching electrode for GMAW of ASTM A572 Gr 60 steel? a. ER70S-XXX b. ER80S-XXX c. ER90S with 20 ft-lbs minimum impact strength at 0 F d. ER100S-XXX e. none of the above 4. For GMAW welding of 3 inch thick ASTM A517 Gr 100 steel, what is the required preheat and interpass temperature? a. 225 F minimum b. 225 F maximum c. 225 F minimum to 450 F maximum d. 225 F minimum to 400 F maximum e. none of the above

Questions 5 and 6 refer to the Butt Joint weld sample.

5. Is the depth of the undercut on this weld sample acceptable if the weld axis is parallel to the primary stress? a. yes b. no c. no acceptance criteria provided d. not enough information provided e. none of the above 6. Is the amount of weld reinforcement on this sample acceptable? a. yes b. no c. no acceptance criteria provided d. not enough information provided e. none of the above 7. Which of the following processes would be acceptable for the prequalified joint B-U2a-GF? a. FCAW b. SMAW
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c. GTAW d. SAW e. none of the above

The following information applies for questions 8 through 13:

A welding procedure is being qualified for the welding of ASTM A572 Gr 60 plate for a structural application. The welding process to be used is FCAW, and the weld configuration is a single-V-groove weld with a steel backing. The thickness of the test plate is 1-1/2 inches. This procedure qualification coupon is being welded in the horizontal position for plate. 8. What is the matching filler metal classification for this base metal? a. E11XTX-X b. E10XTX-X c. E9XTX-X d. E8XTX-X e. none of the above 9. What is the required preheat and interpass temperature for this procedure? a. 150 C minimum to 205 C maximum b. 150 F minimum to 400 F maximum c. 150 F minimum d. 225 F minimum e. 300F minimum 10. For what maximum thickness will this procedure be qualified if the required tests are successfully passed? a. 3/4 inch b. 3 inches maximum c. unlimited thickness d. 3/4 to 1-1/2 inches e. none of the above 11. If the welder who performs this procedure qualification is successfully qualified, in what positions is that individual qualified for production welding? a. horizontal groove and fillet welds in plate b. flat and horizontal grooves in plate c. flat and horizontal grooves in pipe if the pipe is greater than 24 inches diameter with backing or backgouging d. flat and horizontal fillets in pipe e. all of the above 12. What is the F number of the filler metal required for this qualification test? a. 1 b. 3 c. 6 d. 5 e. none of the above

13. What test specimens are required for this qualification test? a. 2 reduced section tensiles, 2 root bends, 2 face bends b. 2 reduced section tensiles, 4 side bends c. 2 reduced section tensiles, 2 macroetch specimens, 4 side bends d. 2 reduced section tensiles, 2 macroetch specimens, 2 root bends, 2 face bends e. none of the above 14. A shielding gas flow rate is 7.5 liters per minute. Using the conversion factors given in Part B, what is the flow rate in cubic feet per hour? a. 15.9 b. 3.54 c. 159 d. 35.4 e. 12.8 15. During the evaluation of a guided bend test specimen, a 5/16 inch corner crack is observed. There is no evidence of slag inclusions or other fusion type discontinuities. The specimen is: a. acceptable b. rejectable because the crack is greater than 1/4 inch long (a space was added between 1/4 and inch) c. rejectable because the crack is greater than 1/8 inch long (a space was added between 1/4 and inch) d. disregarded and a replacement specimen should be removed from the original weld. e. disregarded and a replacement specimen should be removed from a different weld 16. Where should the designation E6010 be placed on the Appendix I form? a. space # 5 b. space # 6 c. space # 7 d. no prescribed place for this information e. this information is not applicable for procedure qualification

Questions 17 and 18 refer to the largest T-Joint sample.

17. Based on the actual size of the fillet weld on Side A, what is the maximum size this weld will meet per the Part B Specification? a. 1/4 inch b. 5/16 inch c. 3/8 inch d. 7/16 inch e. none of the above 18. The discontinuity occurring in the region of the fillet weld from 0 to A1 is properly referred to as: a. root porosity b. linear porosity c. cluster porosity d. aligned porosity e. wormhole porosity

Questions 19 and 20 refer to the smallest T-Joint sample.

19. Is the porosity at location A1 acceptable? a. yes b. no c. cannot be determined d. no acceptance criteria given e. none of the above 20. Is the porosity at location A2 acceptable? a. yes b. no c. cannot be determined d. no acceptance criteria given e. none of the above

The following information applies for Questions 21 through 26:

A welder successfully qualifies on a groove weld in the 5G position on 8 inch, schedule 80 pipe using the SMAW process. The pipe materials are API 5LX, Grades X42 and X52. 21. For what maximum thickness range is this qualification valid? a. 5/16 inch to 3/4 inch, incl. b. 1/2 inch to 1 inch, incl. c. 3/16 inch to unlimited d. all of the above e. none of the above 22. Which electrode classification is an appropriate matching filler metal for this qualification to Part B? a. E7018 b. E7028 c. E6010 d. both a and b above e. none of the above 23. For what range of pipe diameters is this qualification valid? a. 1 inch through 4 inches b. 4 inches and smaller c. 4 inches and larger d. test diameter and below e. all diameters 24. What test specimens were required? a. 2 face bends, 2 root bends b. 1 face bend, 1 root bend c. 2 face bends, 2 root bends, 2 reduced section tensile samples d. 4 side bends, 2 reduced section tensile samples e. 4 side bends

25. What is the required preheat and interpass temperature for this joint? a. none required b. none if the base metal is above 32 F c. 50 F minimum d. 150 F minimum e. 50 F minimum and 400 F maximum 26. What F number(s) apply to the proper filler metal for this application? a. 1 and 6 b. 2 and 6 c. 1 and 4 d. 4 only e. 1 only

Questions 27 through 29 refer to the sample tensile specimen A.

27. What is the width of the reduced section? a. 0.45 inch b. 0.50 inch c. 0.125 inch d. 0.75 inch e. b and c above 28. What is the thickness of the reduced section? a. 0.20 inch b. 5.1 millimeters c. 0.25 inch d. both a and b above e. both b and c above 29. Using the answers from Questions 27 and 28 above to calculate an area, what is its tensile strength if it exhibited a maximum load of 8560 pounds during the tensile test? Tensile Strength = Load Area 68,000 psi 68,480 psi 72,500 psi 74.500 psi 75,000 psi

a. b. c. d. e.

30. If the specimen from Question 29 was taken from a piece of 2 1/2 inch thick ASTM A588 steel, does it meet the specification requirements for tensile strength? a. yes b. no c. impossible to determine from the information provided d. no value for required tensile strength provided e. none of the above

31. If a welder completes a weld joint in the 1G position for a welder qualification test using GMAW-P, in which of the following spaces should that information regarding the metal transfer mode be placed on the Appendix II-A form? a. space # 3 b. space # 7 c. space #12 d. space # 16 e. space # 22

Questions 32 and 33 refer to the smallest T-Joint sample.

32. Is the porosity at location B1 on Side B acceptable? a. yes b. no c. cannot be determined d. no acceptance criteria given e. none of the above 33. The porosity appearing at B1, Side B, would best be described as: a. linear or aligned porosity b. cluster porosity c. wormhole porosity d. elongated porosity e. grouped porosity 34. What is the heat input for a weld made with the GMAW process using 26 volts, 260 amperes, and a travel speed of 6 inches per minute? Heat Input = Amps x volts x 60 Travel Speed (ipm) a. b. c. d. e. 64,000 J/inch 66,000 J/inch 66,600 J/inch 67,600 J/inch 68,000 J/inch

Questions 35 through 37 refer to the sample Fillet Weld A.

35. What rejectable discontinuity exists in the fillet weld on Side 1? a. toe crack b. crater crack c. underfill d. excessive weld reinforcement e. overlap 36. If the fillet weld on Side 3 is measured, what is the maximum fillet weld size it will meet per Part B? a. 3/16 inch b. 1/4 inch c. 5/16 inch d. 3/8 inch e. none of the above

37. Is the undercut on Side 4 acceptable if the weld axis is transverse to the direction of primary stress? a. yes b. no c. no acceptance criteria provided d. not enough information provided e. none of the above 38. What is the minimum yield strength requirement for ASTM A516 Gr 70 steel? a. 38 ksi b. 38,000 psi c. 51 ksi d. both a and b above e. none of the above

Questions 39 through 43 refer to the Guided Bend Samples.

39. Specimen A is a. acceptable b. rejectable because of corner crack(s) c. rejectable because of cracks(s) on the convex surface d. rejectable because of porosity on the convex surface e. both b and c 40. Specimen B is a. acceptable b. rejectable because of corner crack(s) c. rejectable because of cracks(s) on the convex surface d. rejectable because of porosity on the convex surface e. both c and d 41. Specimen C is a. acceptable b. rejectable because of corner crack(s) c. rejectable because of elongated discontinuities on the convex surface d. rejectable because of porosity on the convex surface e. both b and c 42. Specimen D is a. acceptable b. rejectable because of corner crack(s) c. rejectable because of cracks(s) on the convex surface d. rejectable because of porosity on the convex surface e. both b and c 43. Is the welder who welded this test weldment qualified if all the bend test samples are required for qualification? a. yes b. no, because Bend A is rejectable c. no, because Bend B is rejectable d. no, because Bend C is rejectable e. no, because both Bends A and C are rejectable

Questions 44 through 46 refer to the Fillet Weld Sample A.

44. If the shop drawing requires a 5/16 inch fillet weld, is the size of the weld on side 3 acceptable?
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a. b. c. d. e.

yes no no acceptance criteria provided not enough information provided none of the above

45. Which of the following discontinuities are present on Side 1? a. underfill and excessive reinforcement b. overlap and elongated surface porosity c. undercut and overlap d. undercut, elongated surface porosity and overlap e. undercut and elongated surface porosity 46. Ignoring the size, is the weld on Side 3 acceptable? a. yes b. no c. no acceptance criteria provided d. not enough information provided e. none of the above

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VIW Sample Questions

Refer to Part B Book of Specifications for acceptance criteria
1. What is the width of the reduced section tensile specimen B? a. 0.75 inches b. 0.80 inches c. 0.85 inches d. 0.90 inches e. none of the above 2. What is the thickness of the reduced section tensile specimen B? a. 5.8 mm b. 0.23 inches c. 0.185 inches d. both a and b above e. none of the above 3. Using the answers from Questions 1 and 2 above to calculate tensile specimen B's cross sectional area, and the formula on Page 14 of these exercises, what is specimen B's tensile strength if it fractured at a maximum load of 11,030 pounds during the tensile test? a. 75,495 psi b. 79,500 psi c. 84,000 psi d. 89,000 psi e. 89,500 psi 4. What is the area of the reduced section of tensile specimen C? a. 0.12 square inches b. 120 square mm c. 0.17 square inches d. both a and b above e. none of the above 5. Using the answer from Question 4 above, and the formula on Page 14 of these Exercises, what is Specimen C's tensile strength if it exhibited a maximum load of 13,080 pounds during the tensile test? a. 107,000 psi b. 108,000 psi c. 109,000 psi d. 110,000 psi e. 111,000 psi 6. If a welder qualifies on a 3/8 inch thick plate groove joint, what thickness of plate groove joint is that welder not qualified to weld in production? a. 1/4 inch b. 1/2 inch c. 3/4 inch d. 1 inch e. both b and c above

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7. If a groove welding procedure is qualified on 10 inch diameter, schedule 20 pipe, for what range of diameters and wall thicknesses is this procedure considered qualified? a. diameters 4 inches and over, wall thicknesses over 3/16 inch b. diameters 10 inches and over, wall thicknesses over 1/4 inch c. diameters 10 inches and over, wall thicknesses over 1/8 inch d. diameters 10 inches and over, wall thicknesses from 1/8 inch to 1/4 inch e. diameters 10 inches and over, wall thicknesses from 1/8 inch to 1/2 inch 8. Is the porosity in section A3 of the smallest T-Joint weld sample acceptable? a. yes b. no c. cannot be determined d. no acceptance criteria given e. none of the above 9. What is the actual measured weld size on Side B of the smallest T-Joint sample? a. 7/16 inch b. 1/4 inch c. 5/16 inch d. 3/8 inch e. none of the above 10. What is the actual measured weld size of Side B of the largest T-Joint sample? a. 3/16 inch b. 1/4 inch c. 5/16 inch d. 3/8 inch e. none of the above 11. Is the porosity in section B2 of the smallest T-Joint sample acceptable? a. yes b. no c. cannot be determined d. no acceptance criteria given e. none of the above 12. What is the size of the item being measured with the machinist's scale in the sketch below? a. 1 and 23/32 inches b. 1 and 23/64 inches c. 1 and 21/64 inches d. 1 and 21/32 inches e. 1 and 5/8 inches

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13. The width of a rectangular tensile specimen is 0.762 inch. Using the conversion chart on Page 14 of these Exercises, what is the SI conversion? a. 22.76 mm b. 20.69 mm c. 19.35 mm d. 19.15 mm e. 18.77 mm 14. The thickness of the specimen in Question 13 is 18.70 mm. Using the conversion chart on Page 14 of these Exercises, what is the U.S. Customary conversion? a. 0.936 inch b. 0.778 inch c. 0.887 inch d. 0.966 inch e. 0.736 inch 15. Using the required values from Questions 13-14 above, calculate the area of the tensile specimen in square inches and square millimeters. a. 0.777 square inches and 501.294 square millimeters b. 0.555 square inches and 358.062 square millimeters c. 0.738 square inches and 476.131 square millimeters d. 0.561 square inches and 361.845 square millimeters e. cannot be calculated 16. If a tensile specimen fails at a load of 51,550 pounds, and using the values from Question 15, what is its ultimate tensile strength (using the formula on Page 14)? a. 91,889 psi b. 82,800 psi c. 66,400 psi d. 37,000 psi e. cannot be calculated 17. What is the size of the weld being measured with the fillet weld gage shown below? a. 5/16 inch b. 1/4 inch c. less than 1/4 inch d. cannot properly measure weld with the gage shown e. since the weld is convex, it cannot be measured

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18. The fillet weld below is required to be 3/8 inch in size. What can be said about the weld measurement being made in the sketch below? a. the weld is not acceptable because it is too large b. the weld is acceptable c. the weld is not acceptable because it is too small d. cannot accurately determine weld size because incorrect gage is being used

19. The groove weld shown below is required to have a maximum weld reinforcement of 1/32 inch. From the measurement shown in the sketch, what should be said about the weld? a. the weld is unacceptable because there is not enough reinforcement b. the weld is unacceptable because there is too much reinforcement c. the weld is unacceptable because the requirement only applies to the face reinforcement, and the root reinforcement (or face reinforcement if it is a back weld), is being measured d. the weld area being measured is acceptable regarding the amount of reinforcement e. this gage should not be used to measure reinforcement

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Conversion Factors
To Convert From: inches millimeters To: millimeters inches Multiply By: 25.4 3.937 x 10-2

Tensile Strength Formula

Tensile Strength = Load to fracture

area

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