1.

How do we determine what the correct weld preparations (root gap, root face, included angle) should
be?
a) By consulting the WPSs
b) The fabrication drawing will give all the information
c) The welder will decide
d) Welders and inspectors will decide
2.Voltage and amperage meters have been removed from MIG/MAG (GMAW) equipment making calibration
invalid, the equipment should be:

e) Quarantined
f) Only used for tack welds
g) Only sued if validated
h) Monitored closely by the welding inspector for amperage and voltage

3.Which of the following information should the welding inspector enter on an electrode vacuum pack at
the point of breaking the vacuum?

i) Welder’s Name
j) Weld ID number
c) Air humidity content
d) Time and date of opening

4.A maximum inter-pass temperature is generally given to control:

e) High HAZ hardness

f) b) Low HAZ toughness
g) Lack of inter-run fusion
h) Excess levels of penetration
 
5.The WPS calls for a root gap to be between 2mm and3mm, the actual measured gap is 4mm, what course
of action would you take?
a) Accept it as its only 1mm
b) Reject it
c) The welder will decide, if it falls it will be his problem.
d) The welder insists he can weld the butt joint easily so let him go ahead

6.Which of the following welds may be made in an open corner joint?

e) Plug weld b) Butt weld c) Fillet weld d) Any of the above

7.Reference to any inspection hold point during manufacture will be contained within the?
f) Quality manual b) QA Procedures c) Quality plan d) Standards

8.The welders have increased the electrode stick-out length of the SAW set, what would be the effect on
the weld?
g) No effect c) The weld width would be narrower
h) Penetration will be increased d) The deposition rate would be greater

9.Why the OCV capped at a certain level?

i) Save electricity c) Reduce the risk of fatality
j) To prevent exploding of the consumable d) Allow smooth transition into welding voltage range

10. When would you measure the maximum inter-pass temperature?

k) Immediately after completion of each pass
l) Immediately prior to commencing the next pass
m) When the welding is finally complete
n) Maximum inter-pass temperature measurement is not an essential requirement
 
11.The welders have increased the voltage on the SAW, set, what would be the effect on the weld
appearance?

a) No effect b) The weld width would be narrower

c) Penetration will be increased d) The weld width would be wider

12.You notice that a welder is using an unapproved WPS for production tack welding carbon steel,
what action would you take?

b) Have the tacks removed and MPI the weld preparation for cracking
c) Nothing as it is only tack welds and they will probably be removed anyway
d) Nothing as long as the WPS covered the material type, wall thickness and diameter
e) Give him the correct approved one and allow him to continue as long as the welding consumables
were the correct type.

13.You notice the welders are adjusting the current on the welding set, is this allowable?

f) Never
g) The welder has the final say on voltage and current
h) Only if the current is within the range recorded on the WPS
i) As long as the welder has approval from the welding fore-man

14.During root welding, which of the following would be the main cause of burn through?

j) Current too high b) Root gap too small in accordance with WPS
k) Preheat not used c) Root face too large
 
15.You find several unacceptable welds and reject them, the welding supervisor insists they are acceptable,
he signs them off and requests NDT, what action would you take?

a) Nothing as he is a welding supervisor and knows a great deal about welding

b) Raise the issue with the QC department supervisor
c) It is not my problem as he has signed them off so I will not be blamed
d) Look at the NDT results and if they look reasonable I would accept them

16.Why is essential to clean the surrounding parent metal adjacent to the weld metal made by MMA (SMAW
which is to be ultrasonically tested?

e) Sound waves will not travel through paint

f) Remove any rust
g) The spatter will impede the contact of the probe and the parent material surface
h) Spatter will reflect the back wall echo signal and give spurious indications

17.To assess the surface of a weld for direct inspection, the distance from the surface to the eye should
be a maximum of?
i) 200mm b) 600mm c) 60mm d) 6000mm

18.Who should select the specific welds for NDT to cover the 10% contractual percentage required by the
specification/Code?

j) Anyone can select the welds as it’s a random choice

k) The welder as he knows which welds are likely to produce fewest defects
l) Will be referenced in the inspection and test plan.
m) Nobody as welding is always carried out to a high standard the use of percentage NDT is of no real value
19.Who has the responsibility of ensuring the welder is using the correct polarity during welding?
a) Welder and welding inspector b) Store man and welder
c) Welding engineer d) Q/A department
 
20.In a welding procedure transverse joint tensile test the following observations were made. The specimen
CSA was recorded as 30mm X 20mm and the maximum load applied was recorded as 200kN,
What is the UTS?
b) 33kNmm2 b) 333Nmm2 c) 3333Nmm2 d) 33Nmm2

21.Charpy impact tests showing a rough torn surface after the completed test completed test would
indicate which type of failure?
c) Fatigue b) Ductile c) Fatigue to ductile d) Brittle

22.Which of the following is NOT a quantitative test?

d) Root bend b) Macro hardness c) Charpy d) Tensile

23.When transverse tensile testing a welded joint the excess weld metal is often removed.
This action is done to:
e) Allow the test piece to fit accurately into the equipment
f) Reduce stress concentration to the weld toes
g) Allow strain gauges to be placed over the weld face area
h) Allow weld metal ductility to be measured
 
24.In an all weld tensile test, the original specimen gauge length was 50mm and after the test the increased
gauge length was 65mm, what is the elongation percentage?
i) % A is 40 b) % A is 60 c) % A is 30 d) % A is 36
 
25. In welder qualification testing of 10mm plates 2 root and2 face bends were tested. 1 root bend failed
what course of action would you follow?

a) Accept them as 75% were acceptable, you area allowed one failure
b) 2 more root bends should be prepared and tested
c) 2 more root and 2 more face bends should be prepared and tested
d) Retest the welder

26.An STRA test is carried out to determine which of the following?

e) A quick indication of the weld quality for welder qualifications tests

f) The test results can be used to verify that the material has not been adversely mechanically damaged by
g) the heat during welding
h) An indication of the materials’ elongation properties

27.An indication of the through thickness ductility (in the Z direction)

Charpy impact tests show a 50% rough torn surface and a 50% flat crystalline surface after the completed
test, this would indicate which type of failure?

i) Fatigue and brittle b ) Ductile and brittle

c) Ductile with gross yielding d) Fatigue and ductile

28.In which of the following modes of transfer is inductance usually a variable parameter in solid wire MAG
welding (135)?

j) Dip Transfer b) Spray Transfer c) Pulse Transfer d) Globular Transfer

 
 
29.A disadvantage of the MIG/MAG (131/135) spray transfer condition is that it:

a) Cannot be used in the vertical position for steels

b) Cannot be used for aluminum alloys
c) Has a low heat input and is prone to lack of sidewall fusion
d) Is said to have lower deposition rate than dip transfer

30. An advantage of the MMA (111) welding process is that it:

e) Has higher current density than SAW (121) welding

f) Has a very large range of consumables for most welding applications
g) No core wire is lost during the process
h) Requires a lower skill level than other manual forms of welding

31. Which of the following inspection points is most critical in affecting arc conditions during the spray transf
MAG welding (135) process?

i) All electrical connections and contacts c) Gas flow rate

j) Inductance settings d) Electrode coating type

32. Due to the high heating effect in the electrode: when TIG welding (141) with AC it is important that a
tungsten electrode used for AC welding is:

k) Ground to a fine vertex angle of < 30O before welding

l) Used straight from the packet without any grinding
m) Lightly ground to a slight chamfer (comers only removed)
n) Used without grinding and based at 300OC for an hour before use.
 33. When welding vertically up with the MMA process weaving is sometimes restricted to
2.5 x electrode diameter, this restriction is mainly applied to:

a) Reduce the overall width of the weld. c) Limit the heat input into the joint.
b) Reduce the number of electrodes used in the joint d) Reduce the time required to finish the weld

34. An advantage of the SAW process is that:

c) It can be used in the vertical down (PG) position

d) Little or no ozone or UV Light is produced / emitted
e) It is not affected by arc blow
f) It is not prone to solidification cracking

35. A typical minimum OCV requirement for MMA (111) using either rutile or cellulosic electrodes would
be:

g) 40 Volts b) 120 Volts c) 100 Volts d) 50 Volts

36. A typical minimum OCV requirements for MMA (111) using basic electrodes would be:

h) 70 Volts b) 40 Volts c) 100 Volts d) 20 Volts

37. Which of the following would be most unlikely to be found in a butt welded butt joint
using the conventional radiographic method of NDT?

i)  Linear elongated stag inclusions in the root (wagon tacks) c) Lack of sidewall fusion
j) Burn through d) An elongated gas cavity
  38. In a heavy plate fabrication where S is residual @ 0.3%, which may cause problems in the welded joint,
additions of Mn may be added to prevent.

a) Laminations in the plate through thickness c) Stress corrosion cracks

b) Manganese sulphides (Mns) d) Solidification cracking

39.Preheats are used on steel joints of high harden ability mainly to:

c) Slow the cooling rate of the steel c) Remove surface moisture from the joint
d) Reduce the formation of surface oxides d) Increase the diffusion rate of hydrogen into the HAZ

40.Lamellar tears in steel weldment may only be formed when:

e) Using deep penetration welding processes (high current density)

f) High levels of stresses act in the short transverse direction in the steel
g) Martensite has formed in the weld HAZ
h) Low meting point iron sulphide (Fes) has formed in the fusion zone

41.Lamellar tearing is a problem in steels which is always associated with:

i) Sensitizations in the HAZ c) Low through thickness ductility

j) Hydrogen levels above 15m1/100g of weld metal d) Rapid cooling from above the upper-critical

42.Sensitization is a term applied to the formation of which inter-metallic compound at the

grain boundaries in the HAZ of austenitic stainless steels?

k) Chromium carbide b) Titanium carbide c) Niobium carbide d) Molybdenum carbide

 
43. The temperature gradient of steels subjected to post heat treatment stress relief cycle must be
carefully controlled at all temperatures above 300OC in order to:

a) Ensure that a minimum of expensive heat energy is used

b) Reduce the formation of hard martenstic structures
c) Allow the weld to diffuse any hydrogen into the HAZ
d) Heated to a full transformation to austenite then rapidly cooled.

44. For the structure termed martensite to form in a C-Mn steel it must first be heated to:

e) Just below its lower critical temperature and rapidly cooled

f) A maximum temperature of 550OC then rapidly cooled
g) Above its upper critical temperature and slowly furnace cooled
h) A full transformation to austenite then rapidly cooled

45. Which of the following could be used to minimize the occurrence of solidification cracks in steels welds?

i) Increase sulphur levels to a minimum of 0.5%

j) Reduce the dilution into the base metal
k) Increase carbon content in the weld metal
l) Reduce the Manganese content in the weld metal