QUESTIONS and ANSWERS regarding welding

Que.1. What are the welding procedure qualification tests for groove weld?
Ans.1. Tests required for the WPS of groove weld are
A) Tension Test
B) Guided Bend Test
1. Transverse side bend
2. Transverse face bend
3. Transverse root bend
4. Longitudinal Face Bend
5. Longitudinal Root Bend
C) Notch Toughness Test (if required in code)

Que.2. What are the welder performance qualification tests for groove weld?
Ans.2. Tests required for the WPQ of groove weld are
1. Face bend
2. Root bend
3. Side bend

Que.3. What are the welding procedure qualification tests for fillet weld?
Ans.3. Tests required for the WPS of fillet weld are
Macro Test – 5 Nos.

Que.4. What are the welding procedure qualification tests for fillet weld?
Ans.4. Tests required for the WPQ of fillet weld are
Fracture Test – 1 Nos. & Macro test – 1 Nos.

Que.5. What are the conditions for preheating before welding?

Ans.5. The conditions for preheating before welding are
Preheat required if job temperature is less than 10°C.
Carbon content is greater than 0.30% and part thickness is greater than 25 mm thickness.

Que.6. How to reduce the improper penetration?

Ans.6. Preventive measures to reduce the improper penetration
a) Make proper joint design
b) Proper Travel speed selection (travel speed not to be high)
c) Selection of suitable electrode diameter
d) Proper Current (current not to be low)
e) Proper angle of electrode to the job

Que.7. How to reduce the lack of fusion?

Ans.7. Preventive measures to reduce the lack of fusion
a) Proper welding Current (current not to be too low)
b) Proper travel speed (travel speed not to be high)
c) Proper joint design

Que.8. What are the preventive measures to reduce welding distortion?

Ans.8. Preventive measures to reduce welding distortion
a) Proper welding current (current not to be too high)
b) Make proper joint design
c) Tack the weld part properly with fixtures
d) Follow proper welding sequence
e) Joint design should not be restrained

Que.9. Why flux coating is required in E7018 electrode?

Ans.9. Flux coating is required in E7018 electrode because
 a) It is low hydrogen electrode
b) To prevent the moisture absorption in the electrode from environment
c) To avoid the contact of outside air with weld pool.

Que.10. What is the requirement for E7018 heating?

Ans.10. The requirement for E7018 heating
Do as per manufacturer instruction, if not specified follow the following
a) Re-dry at 250°C for 2 hour and then maintain it at 150°C and issue for use in portable oven which is maintain
between 80°C to 100°C. OR
b) Re-dry at 350°C for 1 hour and then maintain it at 150°C and issue for use in portable oven which is maintain
between 80°C to 100°C.

Que.11. What are the precautions taken to reduce oxidation in SS pipe welding?
Ans.11. The precautions taken to reduce oxidation in SS welding
a) Material contamination should be removed
b) Purging gas should be used as per requirement at inside.
c) Purging gas should be used during welding along with Tungsten electrode in GTAW
d) Flux coated electrode should be used in SMAW

Que.12. What are the precautions taken during the welding of SS material?
Ans.12. The precautions taken during the welding of SS material
a) Material contamination should be removed
b) Use tools and tackles which are compatible with SS material
c) Purging gas should be used during welding
d) Avoid the contact of CS material to SS material.

Que.13. Can CS qualified welder perform welding in SS material? Give reason.

Ans.13. No, because the P no. is different, this is essential parameter for welder performance

Que.14. Can welder qualified with ER70-S-2 perform welding with ER309L? Give reason.
Ans.14. No, because the F no. is different, this is essential parameter for welder performance

Que.15. What are the essential variables for welding procedure qualification?
Ans.15. Essential variables for welding procedure qualification
a) P- no. qualified
b) Thickness qualified
c) F-no. qualified
d) Post weld heat treatment
e) Preheat temperature
f) Type of fuel gas

Que.16. What are the essential variables for welder performance qualification?
Ans.16. Essential variables for welder performance qualification
a) Joint (backing or without backing)
b) P- no. qualified
c) Base metal thickness qualified
d) Thickness of weld deposited
e) F-no. qualified
f) Position

Que.17. What are the supplementary essential variables for welding procedure qualification?
Ans.17. Supplementary essential variables for welding procedure qualification
Post weld heat treatment,
Notch toughness requirement (change in group no.)
Que.18. What are the non essential variables for welder performance qualification?
Ans.18. The non essential variables for welder performance qualification
a) Joint
b) Position
c) Technique

Que.19. What are the upper & lower limits for welder qualified in 1 inch NB pipe?
Ans.19. Upper limit: Unlimited, Lower limit: 1 inch NB pipe

Que.20. What is the upper & lower limit for welder test coupon sample of 6 inch diameter?
Ans.20. Upper limit: Unlimited, Lower limit: 73 mm OD diameter

Que.21. What is the upper & lower limit for welder welds 18 mm thick plate?
Ans.21. For base metal Upper limit: 5 mm, lower limit: 36 mm
For weld metal Upper limit: 2X weld metal thickness deposited

Que.22. 3 inch plate welded by GTAW up to 1 inch & 2 inch welded by SMAW by a welder then what are the limits for welds?
Ans.22. For GTAW base metal 5 mm to 200 mm, & for SMAW 5 mm to 200 mm with backing
For GTAW weld metal 200 mm, & for SMAW 200 mm with backing

Que.23. Sample of 3 inch plate is welded 1 inch by one welder and 2 in weld by another welder, what are the limits of welds?
Ans.23. For 1st welder weld metal 200 mm, & for 2nd welder 200 mm with backing

Que.24. What is the reverse polarity and straight polarity?

Ans.24. Reverse polarity: DCEP Direct current electrode positive
Straight polarity: DCEN Direct current electrode negative

Que.25. What is the polarity used for SMAW & GTAW?

Ans.25. SMAW: DCEP, GTAW: DCEN

Que.26. Define code & procedure?

Ans.26. Code: a set of mandatory requirements to get output as per intended use.
Procedure: an orderly sequence of activities describing how a specific technique shall be applied.

Que.27. What are P- Number, Group No., F- Number and A- Number?

Ans.27. P- Number: are assigned to base metal for the purpose of reducing the no. of WPS or BPS. These assignments are
based essentially on comparable base metal characteristics such as, composition, weldability or brazeability and
mechanical properties.
Group No. : ferrous base metal assigned, creating subset of P no. that are used when WPS are required to be
qualified by impact testing.
F- Number: is based essentially on their usability characteristics which fundamentally determine the ability of welders
to make satisfactory welds with a given filler metal.
A- Number: identification of weld metal chemical composition designate on PQR & WPS.

Que.28. Why preheat is required?

Ans.28. Preheat is required
a) To drive away moisture from the weld area
b) To slower the thermal gradient
c) To Slows the cooling rate

Que.29. Why PWHT is required?

Ans.29. PWHT is required for
a) Stress relief of material near weld zone
b) Thermal tempering treatment
c) Refine the coarse grain structure, reduce stresses after welding & remove any hard zones in HAZ.
 d) Regain their original properties

Que.30. What is P- No. of CS, SS, Al & its alloys?

Ans.30. P-No. of CS - 1, SS – 8, Al – 21

Que.31. What are WPS, WPQ, and PQR?

Ans.31. Welding Procedure Specification: to determine the mechanical properties and soundness of weld metal.
Welder Performance Qualification: to determine the ability of welder or welding operator to deposit sound weld metal.
Procedure Qualification Record: It is the record of variable during welding including the mechanical testing and
soundness test of weld metal.

Que.32. How you identify CS & SS after machining?

Ans.32. This can be identified by the following methods
a) By magnet
b) By PMI (positive metal Indicator)

Que.30. What are the welding defects and its causes and remedies?
Ans.30. The common welding defects and its causes and remedies are listed below.

Welding Defects Causes Remedies

1) Excessively long or short arc length 1) Maintain proper arc length
2) Welding current too high 2) Use proper welding current
3) In-sufficient or damp shielding gas 3) Increase gas flow rate & check gas purity
Porosity 4) Too fast travel speed 4) Reduce travel speed
5) Base metal surface covered with oil, grease, 5) Properly maintain and store electrode
moisture, rust, mill scale etc.
6) Wet, unclean or damaged electrode
1) Insufficient weld size 1) Adjust weld size to part thickness
2) Excessive joint restraint 2) Reduce joint restraint through proper design
3) Poor joint design and / or penetration 3) Select the proper joint design
Cracks 4) Filler metal does not match with base metal 4) Use more ductile filler
5) Rapid cooling rate 5) Reduce cooling rate through preheat
6) Base metal surface covered with oil, grease, 6) Properly clean base metal prior to welding
moisture, rust, dirt or mill scale
1) Faulty electrode manipulation 1) Pause at each side of the weld bead when using
2) Welding current too high a weaving technique
3) Too long an arc length 2) Use proper electrode angle
4) Too fast travel speed 3) Use proper welding current for electrode size
Undercut
5) Arc blow and welding position
4) Reduce arc length
5) Reduce travel speed
6) Reduce effects of arc blow
1) Improper tack welding and / or faulty joint 1) Tack weld parts with allowance for distortion
preparation 2) Use proper bead sequence
Distortion 2) Improper bead sequence 3) Tack or clamp parts securely
3) Improper setup and fixing 4) Make welds to specified size
4) Excessive weld size 5) Prepare welding sequence
1) Arc blow 1) Attempt to reduce the effect of arc blow
2) Welding current too high 2) Reduce welding current
Spatters
3) Too long an arc length 3) Reduce arc length
4) Wet, unclean or damaged electrode 4) Properly maintain and store electrode
1) Improper travel speed 1) Reduce travel speed
Lack of Fusion 2) Welding current too low 2) Increase welding current
3) Faulty joint penetration 3) Weld design should allow electrode accessibility
 4) Too large and electrode diameter to all surfaces within the joint
5) Magnetic arc blow 4) Reduce electrode diameter
6) Wrong electrode angle 5) Reduce effects of magnetic arc blow
6) Use proper electrode angle
1) Travel speed too fast 1) Decrease travel speed
2) Welding current too low 2) Increase welding current
3) Poor joint design and / or preparation 3) Increase root opening or decrease root face
Poor penetration 4) Electrode diameter too large 4) Use smaller electrode
5) Wrong type of electrode 5) Use electrode of deeper penetration
6) Excessively long arc length characteristics
6) Reduce arc length
1) Unbalanced magnetic field during welding 1) Use alternating current
Magnetic arc 2) Excessive magnetism in pads or fixture 2) Reduce welding current and arc length
blow 3) Change the location of the connection on the
work piece
1) Incomplete slag removal between passes 1) Completely remove slag between passes
2) Erratic travel speed 2) Use a uniform travel speed
3) Too wide a weaving motion 3) Reduce width of weaving technique
4) Too large an electrode 4) Use a smaller electrode size for better access of
Inclusion 5) Letting slag run ahead of arc joint
6) Tungsten spitting or sticking 5) Increase travel speed or change electrode angle
or reduce arc length
6) Properly prepare tungsten and use proper
current

Que.34. Write procedure format

Ans.34. The procedure has the following chapters
1. Objective
2. Scope of work
3. Applicability
4. Reference Document
5. Responsibility
6. Pre-requisite
7. Equipment, tools and tackles
8. Procedure
9. Precaution
10. Acceptance criteria
11. Records & attachments
12. Distribution

Que.35. What is meant by essential, non essential and supplementary essential variable in welding?

Ans.35. Essential Variable (Procedure): A change in a welding condition which will affect the mechanical properties (other than
notch toughness) on the weld metal (e.g. P-No., welding process, Filler metal, electrode, preheat, PWHT).
Essential Variable (Performance): A change in a welding condition which will affect the ability of a welder to deposit
sound weld metal (such as a change in welding process, deletion of backing, electrode, F-No., technique, etc)
Supplementary Essential Variable :A change in a welding condition which will affect the notch toughness properties of
a weldment (for example, change in welding process, uphill or down vertical welding, heat input, preheat or PWHT,
etc).
Nonessential Variable (procedure): A change in a welding condition which will not affect the mechanical properties of a
weldment (such as joint design, method of back gouging or cleaning, etc).