QUESTIONNAIRE – GENERAL MECHANICAL

What is a PQR?
a. Procedure Quality Report
1 b. Proof Quality Record
c. Procedure Qualification Report
d. Procedure Qualification Record
Answer
2 What should be the content of a “Procedure Qualification Record?
The PQR is a record containing the results of a specific test weld in order to support a
Answer
WPS
3 What is a “WPS”?
A welding procedure specification is a document (normally issued by a welding engineer)
Answer
that guides the welder in order to get the correct weld quality required by the code
4 What information is contained in a weld procedure specification?
All the necessary information for correct preparation and execution of the weld:
- consumable size/type
- thickness range
- type of base material
- preparation (fit up , bevelling, cleaning)
Answer - weld position (1G, 2G…)
- weld essential variables
- weld non-essential variables
- necessity of PWHT
- pre-heat / interpass temperature and method
- ……
5 What is meant by the term “Essential Variables”?
Weld Essential Variables are those who affect the mechanical properties of the weld:
Answer
In case of their change a requalification of WPS is required
Per ASME, to reduce the number of procedure qualifications the base metals have been
assigned “P” numbers?
6 a. True
b. False
Answer
True or False – P-1 are plain Carbon steels per ASME IX?
7 a. True
b. False
Answer
The term “F” number as used in ASME, refers to Filler rods, electrodes or wires?
8 a. True
b. False
Answer
What is a WPQR?
a. Welding Procedure Qualification Record
9 b. Welder Procedure Qualification Record
c. Welder Performance Qualification Record
d. Welding Performance Qualification Record
Answer
10 What section of the ASME code applies to welding qualifications?
 QUESTIONNAIRE – GENERAL MECHANICAL

a. ASME III
b. ASME V
c. ASME VIII
d. ASME IX
Answer
11 What is the minimum acceptable mechanical test in a Welder Performance Qualification?
Answer Bend test
Per ASME - What NDT method, other than visual and bend tests may be used to qualify
welding operators?
a. UT
12
b. RT
c. PT
d. MT
Answer
What position during a welder qualification is best to approve a welder for all positions?
a. 2G
13 b. 3G
c. 6G
d. 4G
Answer
14 TRUE OR FALSE: Qualification in the 6G position qualifies a welder in all positions for
groove welds?
Answer Yes
15 Does a welder need to be qualified when pre-qualified weld procedures are used?
Answer NO
What is an Autogenous Weld?
a. A fusion weld made with filler
16 b. A fusion weld with two different fillers
c. A fusion weld made without a filler metal
d. All the above.
Answer
What is FCAW?
17 a. Flux Cored Argon Welding
b. Flux Cored Arc Welding
Answer
What is GMAW?
18 a. Gas Manual Arc Welding
b. Gas Metal Arc Welding
Answer
What is SMAW?
19 a. Shielded Metal Arc Welding
b. Shielded Manual Arc Welding
Answer
What type of electrode is used in the GTAW welding process?
20 a. Thiorated
b. Tungsten
Answer
21 How are weld electrodes identified per AWS?
 QUESTIONNAIRE – GENERAL MECHANICAL

a. Stamp marking ID data

b. Color coding
c. Label affixed
d. None required
Answer
True or False - A AWS/ASTM welding electrode identified as E-6012 or E100 15, the first
two or three digits relate to the tensile strength of the electrode in the as-welded or
22 stress relieved condition?
a. True
b. False
Answer
True or False – An AWS/ASTM welding electrode identified as E-6012 or E100 15, the last
but one number signifies the welding position it can be used in?
23
a. True
b. False
Answer
24 What is the minimum tensile value of an E7018 Electrode?
Answer 70,000 PSI
25 What precaution must be taken with low hydrogen welding electrodes?
Answer Proper Storage is critical (in order to avoid electrode to absorbe moisture)
What should you do with low hydrogen electrodes that have been removed from their
protective packing before using them?
a. Freeze them for 1hr
26 b. Put them in a holding oven and bake them to remove any moisture
(hydrogen)
c. You don’t need to do anything
d. Don’t use them if they have been removed from their protective cover
Answer
What is the main difference between 7018 and 7018-1 electrodes?
a. None
27 b. One is higher strength than the other
c. 7018-1 is impacted tested
d. 7018 is impacted tested
Answer
28 A primary factor affecting weld ability of metals and alloys is their chemical composition?
a. True
b. False
Answer
29 Raising a materials Carbon level makes it?
a. More easier to weld
b. More harder to weld
c. No difference
Answer
30 The CE Carbon Equivalent formula has been developed to help evaluate the weld ability
of Carbon and alloy steel?
a. True
b. False
 QUESTIONNAIRE – GENERAL MECHANICAL

Answer
31 Some chemistry elements not deliberately added to a melt composition such as Sulphur,
Phosphorus, Tin, Antimony and Arsenic are often referred to as?
a. Special alloys
b. Alloying elements
c. Tramp elements
d. Residual elements
Answer
When making “fit-up” checks, what will you check?
a. Root Gap
32 b. Bevel Angle
c. Alignment
d. All of the above
Answer
The shortest distance from the root of a fillet weld to the face of the weld is referred to
as the?
a. Toe
33
b. Through thickness
c. Throat
d. Cap
Answer
34 What is “Preheat Temperature”?
It is the necessary temperature of base material to be reached before starting welding (it
Answer
is established in the WPS)
35 Why is preheat so critical in welding alloy steels?
- Decreases the cooling rate in the weld metal and base metal (reduce possibility of
cracks)
- Reduces the shrinkage stresses
Answer
- Raises some steels above the temperature at which brittle fracture would occur
in fabrication
- Reduce the tendency for hydrogen induced delayed cracking to occur
36 Some of the primary reasons for preheating a Carbon or Low Alloy steel?
a. Reduce the tendency for hydrogen induced delayed cracking to occur
b. Reduce shrinkage stresses
c. Maintain weld Inter-pass temperatures or reduce cooling
d. Raise the temperature up to the preheat temp stated on the WPS
e. All of the above
Answer
37 What is “Inter-pass temperature”?
It is the necessary temperature of base material to be maintained during welding (it is
Answer
established in the WPS)
How would you check the preheat or inter-pass temperature of a weld?
a. By placing your hand close by and guessing the temp
38 b. By contact thermocouple
c. By temp crayon
d. Either B or C
Answer
39 The size and width of a HAZ (Heat affected zone) is dependent on the heat input used?
 QUESTIONNAIRE – GENERAL MECHANICAL

a. True
b. False
Answer
40 What is the purpose of post weld heat treatment?
Answer Stress relieving after welding
41 The primary reason for post-weld heat treatment is to relieve the residual stresses in a
welded fabrication?
a. True
b. False
Answer
42 Difference between stress relieving and normalising?
stress relieving is intended for reducing the stress cause by machininig, welding or rolling
with the scope of avoiding distortions or cracks
Answer
normalising is intended for refininig the structure of the steel with the scope od modify
its hardness
43 True or False: After stress reliving operations have been completed, major repair welding
is permitted with the authorization of inspector’s concurrence?
Answer False
What is shielding?
a. Shielding is a welding method
44 b. Shielding is a method of thermal protection by blankets
c. Shielding is the method of protecting the weld pool with gases or fluxes
d. None of the above
Answer
45 Why are shielding and purging gases used in welding?
Answer In order to protect the pool from atmosphear gases
Personnel carrying out Visual Welding Inspection activities are required to demonstrate
annual completion of a J-1 Jaeger-type eye vision test acc. to ASME V art. 9
46 a. True
b. False
Answer
A discontinuity is a defect that is reject-able?
47 a. TRUE
b. FALSE
Answer
What type of defect may you expect to see during a visual examination of the prepped
edges of a steel plate sections away to be welded together?
a. Laminations
48 b. Slag
c. Undercutting
d. Overlaps
Answer
49 What typical defects would you expect while inspecting a casting?
Answer Porosity
Lamellar tears, de-lamination and laminations are all base material discontinuities?
50
a. True
 QUESTIONNAIRE – GENERAL MECHANICAL

b. False
Answer
An inclusion is an entrapped foreign solid material such as slag, flux, tungsten or oxide?
51 a. TRUE
b. FALSE
Answer
52 What typical defects would you expect while inspecting a completed weld?
- porosity
- inclusion
- cracks
Answer
- undercut
- slag

Suck-back, Underfill, crater cracks and Porosity are all Weld Metal discontinuities?
53 a. True
b. False
Answer
A bend test of a weld specimen is used to evaluate the?
a. Tensile strength of the material
54 b. Yield strength of the material
c. Toughness of the material
d. Ductility of the material
Answer
55 How will you determine the “yield strength” of a component?
Answer
A Charpy impact test consists of how many specimens?
a. One
56 b. Two
c. Three
d. Four
Answer
57 Name 2 tests carried out to determine toughness.
Answer Charpy and Izod impact tests
58 What type of additional testing is required for materials in wet sour service to meet the
requirements of MR-01-75?
Answer None
59 What is max. hardness valve as per NACE MR 01 75?
Answer
60 How does a Certificate of Compliance differ from MTR?
Answer
61 What info is required on a standard mill cert?
Answer
What mechanical properties are normally specified in steel mill test reports, and in what
62
units?
Yeld stress (MPA)
Answer Tensile strenght (MPA)
Elongation (%)
 QUESTIONNAIRE – GENERAL MECHANICAL

Hardness (HBw)
Impact test (J)
63 How would you measure gramophone lines on a raised face of a flange?
Answer
64 Name at least 3 type of flanges
Blind flange
Answer Threaded flange
Slip-on flnage
65 What is a mil?
Answer A thousand of an inch