THE DUTllES OF A WELDING INSPECTOR:

My duties as a welding inspector are involved before, during and after welding.

Before welding:
• All applicable documents are checked; ..,
• Application standard is up to date with the latest edition, revision or amendment;
• The drawings is clear and issue number is marked;
• Welding procedure sheets (specifications) is available and has been approved as required
by authority and is employed in production;
• Welder qualification with identification and range of approval are verified and that only
approved welders as required are used in production;
• Safety permits such as gas free (entering enclosed space) certificate, hot work permit are
available and valid;
• Calibration certificates, material certificates (mill sheets) and consumer certification are
available;
• Quality plan is authorized and endorsed with signature, date and company stamp;
• Parent material identification is verified against documentation and markings;
• Material composition, type and condition are checked;
• Identification of welding consumables such as electrodes, special drying requirements for
electrodes, filler wires, fluxes, shielding and backing gases are verified correct;
• Plant and equipment are in a safe condition and adequate for job;
• Correct methods are applied in cutting and machining;
• Dimensions, tolerances, preparation, fit-up and alignment are in accordance with approved
drawings;
• Cleanliness is maintained;
• Preheating for any tack welding is in accordance with specified procedure;

During welding:
• Welding processes such as root pass and tack welds must be monitored and inspected;
• Welding should be completed without undue interruption and within specified period;
• Hot pass must be timed;
• Essential variables such as current, voltage, travel speed and number of runs must be
monitored;
• Inter-pass cleaning, temperature and run sequence should be inspected (roving
inspection);
• Welding is in compliance with welding procedure sheet and application standard.

After welding:
• Dimensional )3ccuracy must be checked;
• Visual inspection is carried out to ascertain acceptability of appearance of welds;
• Post weld heat treatment if any should be monitored and recorded.
• NOT report is assessed; __
• Delayed inspection is carried out 72 hours later to check hydrogen((f::g)cra9_kiQJJ)
• Factors influencing the formation of weld defects and their acceptability in relation to the
written specification are appreciated.
• If repairs are required then:
1 Procedures and welder codes should be authorized.
2. Defect area should be marked out positively and clearly.
3 Partial and fully removal should be monitored with visual inspections and NOT.
4 Re-welding should be monitored and re-inspected (visual and NOT)

Collate all documents and reports, pass on for final inspection, approval and storage.
 THE WELDING INSPECTOR
I
RESPONSIBILITIES

+·
ENSURE
t
ENSURE
•
ENSURE
COMPLIANCE WORKMANSHIP WELDING
TO STANDARD OR CODE CRITERIA BY .

1
_ _ _ _ _ _ __..., ATTRi'BUTES ·~--------11
"POLICING" WORK &
(DOCUMENTATION)

HONESTY LITERACY FITNESS

INTEGRITY I
f
PHYSICAL
•
EYESIGHT

·· _ _ _ _ _ _ _ ___. D~TIES ~ I I
OBSERVE
MEASURE
IDEfTIFY

BE,ORE DURING . AFlER

WE~DING W~LDING WE~DING

MATERIAL VOLTAGE P.W.H.T.

CONSUMABLES AMPERAGE VISUAL
WELDING PROCESSES TRAVEL SPEED ASSESSMENT
JOINT FIT UP INTERPASSTEMPERATURE NOT
PREHEAT INTERPASS CLEANING ASSESSMENT
TACK WELDING/CLAMPING
ALLIGNMENT
CALIBRATION

.----
SAFETY

ACCEPT REJECT
f
+
COLLECT & COLLATE
AL~DOCUMENTS

WHICH MAY INCLUDE:

CODE OR STANDARD
RE~AIR

1.D.AREA
MARK OUT
REMOVE
RE-WELD
l
CONCESSION

MATERIAL CERTIFICATES RE-INSPECT

CONSUMABLE CERTIFICATES
CALIBRATION CERTIFICATES
DRAWING(S)
WELDING PROCEDURES
APPROVAL CERTIFICATES
INSPECTION RECORDS 1 - - - - - - - - - ACCEPTANCE OF THE PRODUCT
P.W.H.T. RECORDS
OTHER TEST RECORDS
CONCESSIONS
COMPLIANCE CERTIFICATES
•
INSPECTOR PASSES THE
DOCUMENT PACKAGE TO A HIGHER
AUTHORITY FOR FINAL APPROVAL
 -- ....._
Page 8
EN 287-1 1992

-,
5, J Welding positions
Foe the purpose oi this standard the welding positions identified in figures 1 and 2 shall apply (according to ISO 694 7). Angles
of slope and rotation for straight weids in the welding positions sha'I be in accordanc!! with ISO 6.94 7.
The positrons and anqles used in the approval test shall be based on the same tolerances as used in production.

({(( ((( (((((( (((( (((((

PA Flat PC Horizontal vertical

I
PE Overhead

I
Jen1cal downwards
1
?F Vertical upwards
I
al Bvtl welds
I
I
f';\ Flat ?8 Horizontal vertical
I
··'

I
PO HorizontJI overhead I
?F' Vert1c,1I upward~ I

bi Fillet welds
I
Figuro 1: Welding positions for platos
I
I
 ~TI..DDiC PCSITI~ (BS l.99: 199t/rso 6~7)

PD
no,izon::..al ove~hca~

. ..; .. . , . -
. - ": .... ~·..· .:-:.:_-:.~
.. ..... ._ ---·· .

:-'.o-: £ :on::.1 t

?S
Ho•i:on::.ll ~~~tic~l

,., - -
1 1 co~~ c~n~~s~o~ ..........
I, . \~ J~~~=~J!~
.- -'
 BSEN STANDARDS
- -

I .. --
TITLE I NUMBER DESCRIPTION
1 !\SEN 970 VISUAL INSPECTION OF FUSION
1--- ' JOINTS
. BSFN ISO 15614 parts 1-6 WELDING PROCEDURE
QUILIFICA TION TEST (for steel &
-
aluminium)
ISO 9606-2 WELDER QUALIFICATION TEST
--- -- ---- --------------
(aluminium)
. HSl·:N 287 WELDER QUALIFICATION TEST
,,.
(steel). ---·----- - - - ····-------- -- --
ii 1\Sl·:N ISO 5817 i\l'l'l·'.Cl'Ti\N< 'E CRITRI/\ (for steel) __
1
llSl·N :.1: 'i 'i I WFI .DIN< i S YMIH >l.S

---- -- ------- -------------

--- --

-- ------~----

-----------
.
-- ------

- - - ----------·-

----------- ---·-------

--------- - - - - - - - - - - -
A r.JS System

American Welding Society Specification: ANSl/AWS AS.1·81

Ct111lnutJ011 Tenelle ttrtflfd\,

N/mm•
Y11ld '"'"""-
NI"""'
E6010 430
. IO
(60\1 430 50
(6012 '60 380
(6013 '60 380
(6020 430 )40
E6027 430 )40

E70 500 '20

~E6020 -
Flu•
CIAulollic E- - -o
f - __ ,

l---2
- lllutlle
(---J

...
lllU'tlle
powd«

Balk+ ~-
+ Rn (---4

1---·
1---·
1---·
( - - ' -
( - - 2-
Al '°"'*"
Hotilon..i fllltt
·~Rat
E- - J - 1l~t ollflf

U1c1ric1I cher1ct1rf1da
0. aaifou lion Iii; DC

..• ~•M
P'ositM
U010
EeGt1 J '
I
£6012 JI ' •
~
E601J
(6020 • '
£6027 .
•'
nou .I

.... 'I
£701S
£7016
E7011
.. ..
[702•
E 7027
.. .;'
.;
E 70711 . ,·
British Standards System

BS specification: BS 639: 1986

FIRST GROU, CO V E ~ING EfJlCltNCY (HJ

Elee ttodt Tenlii. Minimum yi•ld I bnc 'l rtcov• rr to lndicatu
de5ignat1on 1trtngth, atreu. N/mm1 JIJI hi;h • ffic 1•ncy .,.., ... 10" hydrogen
N/mm 1 calluloe c 1> 1101
E4J tJO. 550 330
!
I\
0•1di .. ng
run• !medium co.atedl
con1tolled
I< 1Sml/100QI
ES1 510-650 380 M 1u11i. lhHYy c:o1t.edl
s ottiet ty1>41

E 51 33 I 1eo 2 0

SECOND GROUP POSfTION OtGrT

t
EU CTRICAl DIGIT
f""1t1t Tam per 11u11 f()( 1 an po1itiona Code Di11C1 current Att.1nati"9 current
dlQlt im~value of 2 all potitiona except venical down
1&.I, "C l l\tt end, fOf fillet welda, horlzontll vertical ~nt•nd<td Minin".i~ 094ft"
ti.c11'od. ci" ~ "° rt..ge. v
,
0 "°' ~if.. d
+20
'
I
l\tt
ftal. ,,.rtical down and, fOf filS.t w11d1.
poi.1ify
horilontal venic* Pollritv .. Not auluble for
2
l
0
- .i)
I any position °'
combin1tion of po1ition1 not r.eomm.i nd4d UM onA.C
clauif',.d abooi.1 W rNnvfiM:-
' -)()
0 'luAI

'
Se<: and
-40
Ttmpe111Ur• IO<
, +or- 50
digit imp.et velu. of J 50
47J. '( l + !50
+or- 10
0
, No I l(>eC ifled
+io
'5 70
2 0
e + 10
J -io 1 +or- 80
~ -)()
I 80
s -~ 9 + eo
6 -so
7 -60
8 - 7()
·-------- -
 -·
.ui., .._,..., Ct.-.JoJ c•·~•U.•'""'
w.
No symbol
""'
z.o - '"-
Mo l,C O,l • 0,5 -
Mn.'fo > l,C • 2,0 O,l - 0,6 -
lNi l,C - 0,6 - I,?
ZNi l,C - 1,8 - 2,5
lNi l,C - > 2,5 -l,8
!MINI > l,C • 2,0 - 0,5 - 1,2 Hrtn-c ...
....... C....C..•I ....VIGO' ..u.-.
lNU(o 1, C 0,l - 0,6 0,6 - 1,2
z HS S
Iv"! o<h<r ·~ C'Ompaddon
HIO 10
HIS IS

~
S,->-1 h-u.c M.l.al.oo ... A - acid C'OY'C M.c
___..,
,w.c ~
~·· c - cd.lulosic °""'"""'
-..• 111 .... • K R - rutilc~rlnc
1S l.SS 440 - 1570 Z:? RR - rutilc tJUcJt ~rlnc
J.! lSO HO - 5CO 20 RC - rutilc-<eUWosic ~
I~ czo SOO • 6-41> 20 RA - rutilc· M:id ·~rU\&
46 460 SJO - 680 20 RB - NtiJt"-buiC ~nn,

5J SOO 56) - 720

IS.' 8 - t..uictrlnc

EN 499 E 46 3 lNi B 54 H5
T\ .... ,...,.,,... f•r -1.&.I.-• ..
/
•-"'4• l..-,.....c"t
\
l J .lU porition.s;
•.....-a""' 21 .lU posilion.s, ucc;>( ""nioJ ~own;
"C
JJ rue bun weld, IU1 ri11ce weld, hori.zonu:
l No ~ui.n:mcnl veniol rilltl weld;
A • 20 CJ rue buU wdd, ru1 ri.llce weld;
0 0 SI ~o.J down &J\d pooili<l>N ~~nlina 10
2 - 20 J)'mbol l.

- JO
- co
- 60
- 60
-,14 .......... ...,..._....., l"r'rr .r "'""·••••
s
I s IOS •.c. • d.c.
2 s IOS d.c.
l > IOS s I ?.S a.c. • d.c.

s
> 10$ "' I '!S
> 12S s 160
<let.
•.c.
d.c.
.
d.c.
5 > IZS s 160
7 > 160 a.c:. • d.c.
a > 160 d.c.
 auo®@J®@ orru ®~®@0
~®W 'w@[f@J®
06-02-01
A 13 Whit"etkeY

Hydrogen induced HAZ or weld metal cracks. Key words:

Cause: Hydrogen. Moisture. Consumable type. Absorbtion. Paint. Oil.

Solubility. High harc:fenability. HAZ hardness. Martensite. Diffusion.
Trnnsformulion. Hardness. Stress concentrations. Weld toes.
Delayed inspection 48 hours after welding.
The four critical factors and levels.
>15ml H2 • VPN> 350. Temperature< 300. Stress> 0.5 YS

Hydrogen Weld metal cracking (High strength low alloy steels)

Increased carbon content to match of parent metal strength.
Higher hardenability in the weld metal. Transverse cracks

Prevention: Preheat. Hydrogen control. Consumable checks. Low H2 process.

Restraint. Remove plate coatings. Control of stable arc length.·
The four elements to consider when calculating pre- heat.
Arc energy. Joint design. Carbon equivalent. H2 content.
Austenitic stainless steel weld metal.

Solidification cracking in C/Mn steels. Keywords:

Cause: Sulphur. Fe/Sulphides. Weld centreline. Contraction.

Low m. p. films. Contractional forces. Loss of cohesion.
Low strength hot shortness of solidifying weld metal.
High Mn/S:Carbon ratio

Prevention: Manganese. Low dilution processes. Lower carbon ratio.

Restraint. Avoid aluminium deoxidised wires. Low sulphur plate.
Minimise contractional strain.

Lamellar tearing in C/Mn steels. Key words:

Cause: Poor through thickness ductility. Below HAZ.

Plastic strain. Sulphur laminations and bands. Contraction.
T joints. Corner joints. Stepped like crack.

Preverition: Buttering layers. Contraction gap. Fillet welds. Re-design.

Dornier plates. Reduce restraint. Control heat input.
Maximise ductility in weld metal and minimise strain.

1
 Maximu m pore diameter 3mm or
pore diameter shall be less than or equal to 0.3
X plate thickness Table 1 - limits for lmP.,erfectlons
Llrnltt ror 1moerf« tiar11 I'!< , ...n rv ,.,,.,.
ISO un ~ •nu r ta Moduala
[)
i' lt>l(>':Tl~l •I~
c:
I . ''' n~cnl 8

t-r ~ c•• •lnft)l!•..,11

o:"..l-;\111 er.it.; •OJ P~ml~t:'~ "'•:-" C'f,.,,..•1r!CI

PN0;1r, '°d I :Ot 1

'7H r•or1>• :o r2

,, I I ~<.

µ;i:
I
t l ~t;r'' "''""' 01m~"' ' "'" of ~ 1rr~ c :-"'' •~· 1·

t>v· ~ .... ,~ ~ d" 0.! :

I 111~1 ...... ,
-
I i:: t.t.2.\&- 1~,_ dlr1''\•f'~1 ~~ ·~r ~ "'""';1~ f":'.:,. 5 -m ' .,.., :7"1

\o~~I p:u~ ~'f;ill 111•:-• 1." ·r.. "tV!t~~--~:­

1
;f,I • -t-t
... u:!t""~ : 1 HTU":i~ •n;! ~1..c..l iii'-• A4. A C--"'• "-•t;i;,f f)f t•p
r!,rrt.. c1•.1f•• ""t 1"'• .... .._ ,.~~ ~ ... o-....-·~ ·~: 'f'""·=
./ l"lQ ~ll !,..... :i<:irc: O'" ~ .-: 1·c 1t ...,11"1 ..l ·1 1 ~vnP~• · -:,:,;,. .
I ·~ ; .,.,,...,; ~
Acceptance levels Bj,C,/D I
r tspo r <t1rrQ !:-

.,.., Ptt r m 1 ~·~ ~"'.' ·~· ci; ~' •~

....,.·ah

~ hn1 1 -: ~ >e r.i<: . : i ."1.:J

i p ci:~ r :> t l · r,. cl ""oa1•:.· ~ -;-"!"\'::' ., , ~ =-" ~ ~ti,,.•!

For the CSWIP 3.1 e*am '> :'l r: U ~ -~ fJoli! t.1•,..,, r,,(r; C"'.'1'·~ 1 ~~·.;ii • 1 .:. -

I r~ l o('('1'" · - ; ::" n fj ,!•r.irs Cs"' ~ ' . r""""t -s. '. •

stringent B I ""~~ r ~~""". · i: r · ~ ~~ 1 .! 11 t ic 1
_ :r1 ~· ~

Ji ,.., ~ .. · -- ,. ~ ;,~, !!: .-'; <'· .... .._1 ~ ~ •. ~- ~ · .. ~

;11 ~ · c-:"" e- : : "' : _ __.. J · ' · ·: !'". Ji• ,;. .:. I · ~ c.

. ~ ,.P. -- • .

I ,. . . . .
. . .. ' - •. ··.
C uJ.Jy r 1yt " 2006 Tw1 UcJ
 Page 6
ISO 5817 : 1992
- -- .. .. - -- --

1SO5817 (BS EN 225817)

3..2 Weld thickness 4 Symbols

3.2.1 fillet weld thJcknea s, a; nominal throat thick- Tho followi ng symbols are used in tab l e 1
ness: Height of the largest Isosceles triangle thal
a nomin al Ol let we ld lhroat lhtckn es s (fill e t 1h ick-
can be Inscribed in the weld section {see ISO 2553) .
n ess)
NOTE 1 In countries in which lhe ~ lengtl'\, z. is used
as the dimension of a fillet weld. the limits for
b w idth or weld reinforcemenl
imperfections may be reformulared so that t~y ref.er to d diameter of pore
\he 'eg \eng\h.
It size (hei~ht or width) of imperfection
J.2.2 butt we-td thlcfcness. s: Minimum distance rrom
the surface of the part to the bottom of the pen-
I length or imperfecticn
.,, etration. which car.not be greater than the thickness J nominal bull weld thtclrness or. in the case or
of the thinner of the p3rts (see ISO 2553) partial pene1ration. the prescribed depth or pen-
etration
3.3 short •mperfectlof'd: One or more lmperfeciions
of total len gth not greater than 25 mm In any r wall or plate thickness
100 mm length of the weld or a maximum or 25 %
" leg length of nllet welds (in case of isosceles
of t~e weld length for a weld shor1er than 100 mm 1
right angle triangular section :: =a ..., 2 >

3.4 lo-ng Imperfection: one or rnore imperleclions

5 Evaluation of welds
or 1otal length greater than 25 mm In any 100 mm
length of the weld or a minimum or 25 %1 of !he weld Limits for imperfections are given in table 1.
length For a weld shorter than 100 mm
A welded joint should normally be evaluated sep-
3.5 projected area: A:--ea given by length of werd· arately for each individual !ype or imperfection
examined muftiplied by the maximum width or weld (Nos 1 to 25)

OifTerenl types of 1mperfect1on occurin9 at any

3.6 sur1ace crack area . Area to be c o ns i d ered ;:i fh: r cross-sect ion of !he joint may ne ed special con-
fracture sideration (see No 261
 SPECIFICATION PH6/Wl/OO

PLATE ONLY
KEY:
L = Lengtb of defect
D = Depth or height of defect
W =Width of defect [applicable to inclusions only]

i-#--T6 EFECT NAME REMARKS MAXIMUM

-- --- - -- · ---
-
: ALLOWANCE
~--
1
---·-·· -
Cracks Not oermitted
2 Porosity/Gas pores/Elongated gas Maximum dimension of any area Imm
1-- -----
cavities [Wormholesl/Pipcs or individual fas applicablel
-- ---- _.9'.".'. ~r!<lP... ---·················----------············· ·---···--
3 Accumulative total for both 20mm in weld
4 Lack of sidewall fusion defects shall not exceed 20mm Face lenl!th
5 Lack of root fusion
-- -- - - .. -- ----- -- ·-·------- ------ -·----- ------------·· ···----------
Accumulative total for both 20mm
-
6 Lack of penetration defects shall not exceed 20mm In root len~th
7 Inclusions [slag/silica etc] Accumulative total shall not Individual
exceed 15mm total "L" in weld maximum
' L<12mm/W<3mm
-·-· 1- --- --- -
.. .
Jenirthr root&face indeoendentl
3 Undercut 10% t up to a
I

---·-· --- -- ·--·

maximum D 1mm
~
9 Root concavity maximum D 1mm
10 Underfill/incompletely filled Not permitted
- ·
groove/Lack of fill
11 Linear misalignment Maximum D
<tomm t-1.0mm
I >tOmm t-1.Smm
-1-2 tA~-~trikes/Stray flash Not permitted
- ·- - ----
13 Mechanical dama~e Dependant on depth and blend Seek Advice
14 , Angular misalignment Accept
I
----
-+- -
I~ , * Smooth transition is required/ All 2mmD
1
- i Excess weld metal runs shall blend smoothly. maximum
i
--16 -+-: E -- . *
No lack of interun fusion
J.SmmD
i :xcess penetration maximum
I ·--- -- ---- ----- -·-- - - ·--- ---· - -·· ··· ·--- -- ·- - -- ·· -- -··---------· - --- - -- - --·-·---··- ·- - - - ··· -·-----·- ··- - --·-· -------------- -- -
*When linear misalignment is present the following shall he applied:
Exce" ~ weld metal:
Maximum height to be measured from a direct line from "lowest plate", across wcldment.
Excess penetration:
Maximum height to be measured from "lowest" plate.

L -t
t
'•! TWI I TD PH6/Wl/OO
Rev 1May00
 Hydrogen induced HAZ & weld metal cracks

Transverse weld
HAZ cracks metal cracks

Solidification cracking

Crack occurs at weak hot~--_.

short weld centreline due
...
_

to tontractional strai~J

Lamellar tearing
Tensile test used to assess the likelihood
of lamellar tearing occurring. Lamellar tear caused by
contractional strain in
the through thickness
direction

Butter with high Redesign

ductility weld metal of joint

Forged T
Piece

2
 Kgern~(C ftli(021tils mWceliOOcdl J~Riruta 0 11.23

Welding imperfections can be categorized into groups:

1) Cracks
2) Gas Pores & Porosity
.1

3) Solid Inclusions
4) Lack of fusion
5) Profile & Lack of Filling
6) Mechanical or Surface damage
7) Misalignment*

:._.Gp y:1g r,~ ,:~ UU.: ,,' : ~ ,:

lext Page Ref J: I
 Wellcdl §ymmlbce»ll§ OIDl DILatwli101ga 11.40

.
Weld Symbols on Drawings
BS 499 & A WS A 2.4

/Jl
/ "'-
. '/ 8 ~1
I - ,
~-- -· - .
n
i I
a5 b8 *

Copyright© 2002 TvVI Ltd

No Text Reference
 A W©lidlirrng fu§JP©cctors Icox02Jlb(())x__ 11.18

.
A Welding Inspectors toolbox should contain*
A welding gauge (Cambridge style, or high low gauges etc)
A tape measure and scale

,, A wire brush
A magnifying glass
A torch and mirror
A specification, pen and report, or note paper
Any other aids to \-isual inspection*

.__,- 0
~
~· _· , · i
'
'' j
.. ~
I __, ...:_
'
•._,I \ ....: .._,. t f
'\ o I t' \ t Refe r~ n l' t>
 §Joecica1Jl]s~dl Aids f C02Jr liml§JD)©(Cftli~lPl 11.20

.
Inspection may utilise the following specialised equipment:*

Boroscopes (For assessing root runs in small 0 pipes)

Flow-meter (For measuring gas flow rates in MIG/MAG/TIG)
·. f
Simple NDT equipment (Penetrants and MPI)
Complex NDT equipment (Radiography or Ultrasonics)
Note: Both simple and complex NDT methods requires the
specialised skills of qualified operators/technicians*

:::
,_.u py ; 1g 1ii '':'. ·
- , r . r --
( i.J l .1.:
""':"""-
I
~

v V• I 1i )
\o I ext Reference
 Welicdl §ymoilbx02li§ C02IDl DrawiIDlg& 11.45

Weld Symbols on Drawings

BS En 22553 (ISO 2553)

z8
---- -- or - - - .
z8 V

a 5 z_S G- or - r7 .
-- a5z8 V *
-(/8~1' s

C op yrigh t © 2002 TVV I Ltd

No Text Reference
 Remember! The process of inspection is to first:
Observe, then Report, then Compare!*

.,,
Use the T\\1 macro sheets provided to observe and then
make a report on a separate sheet of what you observe*

When you have finished reporting, turn the macro sheet

over and compare your observations with those given on
the back of the sheet* (1 hour)

r·· o r1
\_, r-- Y!~·I g 1l-t ,,,_,J
1 \S 200''
'L T' ' /I ;L
I ', i/!
· ~
LU
.\o ·rext Reference
 Welicdl §ymlboli§ (Q1Dl DJrcalwinga 11.50

Example:
Produce a drawing giving symbols for the welds
given as shown below to the specification given
Weld Drawing BS 499
MMA

Example:
Symbol Drawing

-
-*,. -~I I* ,

Copyright © 2002 Tvvi Lto No Text Reference

 1Cce§fcium.g ilice Wcelicdlm~rrmt 13.25
The test weld is usually cut into sections as follows:
The location of specimens will depend upon the standard

Charpy V test Bend test*

.,

Tensile test . M acro/Hardness te ~ t

Start/ Stop

(\._/ \...I
"r r
" r' q
,..._, y
n ' tI
I .....,. I
'C.
""'-=-'
£._
; U( i
'-../ L
/ ·I. \ , -,
'I f
i 1· '
l._
l,..,
V
~o 'lext Reference
 The main difference between Macro & Micro is that Micro is
the study of the micro-structure at much higher magnification
The limit of Macro inspection is magnification< X 10
.I

The specimen is usually cut from a stop/start in the test piece

r-fhe cut specimen is polished to a fine finish (400 grit)

The specimen must be inspected~ before etching*

C op yri g ht@ 200 2 T ,N ! Ud

1\o l ext Reference
 JFILJlfS2iilbJli~ lIIDl§©Jilt§ 14.04

Before welding

,, After welding*

A fusible insert is pre-formed and placed filler material

that is mainly used in the root of TIG welded pipes*

It is often termed an "EB insert" after*

The Electric Boat Company of .America'! who developed it *

Copyright © 2002 TW I Ltd

No Text Reference
 MATERIAL INSPECTION
(CARBON/LOW ALLOY STEELS)

INSPECTION OF
I
• ..----- t

.
SIZE TYPE CONDITION

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COMPOSITION
~-
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THICKNESS GRADE PHYSICAL MECHANICAL
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TWI SENIOR WELDING INSPECTOR
~IL_ ',_ " .;.> .. ,, • • - ... • • ~ - -:· - ~ .. THE WELDING INSTITUTE

A MERICAN WELDING SOCIETY

STANDARD WELDING SYMBOLS*
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 \Vclding Inspection: Multi-Choice Questions Paper I (Rev. 2)

...
Which mechanical test can be used to measure the toughness of weld metal, HAZ and paren t ma1 ?

A macro
B nick break
C hardness
D Charpy impact

Winch is the best destructive test for showing lack of side-wall fusion in a 25mm thick butt weld?

J\ nick hrcak
B side hcml
(' ( 'hnrpy impact
D a face bend test

The principle purpose of a welder qualification test is .

A to test the skill of the welder

B to assess the weldability of the materials
C to decide which NDT methods to use
D to give the welder practice before doing production welding

'' A fabrication procedure calls for the toes of all welds to be "blended in" by grinding.
The most likely reason for doing this is to .

A make the weld suitable for liquid (dye) penetrant inspection

B improve the fatigue life
C reduce residual stresses
D improve the general appearance of the welds

hir fu II penetration single-sided butt joints, root bead penetration and profile are mainly influenced by .

A root face
B bevel angle
C root gap
D included angle

,, lJndercut may need to be assessed according to ....

A depth
B length
C sharpness/profile/blend
D all of the above

When visually inspecting the root bead of a single-vee-butt weld it should be checked for .

A lack of root penetration

B llAZ hardness
C tungsten inclusions
() all of the above

I WI North . Mi<ltllcshro11gh
Welding Inspection: Multi-Choice Questions Paper l (Rev. 2)

Please return this paper unmarked

8 The strength of a fillet weld is determined by

A leg length
B weld profile
C weld width
D throat thickness

'! The Furopcan Standard for NOE of Fusion Welds by Visual Examination is ........ .

A EN 288
B EN 499
(. EN 287
D EN 970

Io V 1s11al mspection of a fabricated item, for a high integrity application, should cover inspection activities .........

A before, during and after welding

B before welding only
C after welding only
D during welding and after welding only

II Incomplete root penetration in a single-vee-buttjoint may be caused by

A an excessive root face

B an excessive root gap
C the current setting being too low
D both A and C

12 Incomplete root fusion in a single-vee butt weld may be caused by ........

A linear misalignment
13 the root gap being too large
C root faces being too small
D all of the above

Il When visually inspecting the face ofa finished weld it should be assessed for .........

A maximum excess weld meta\ height

B toe blend
C inter-run blend
[) all of the above

I ·l /\ bum-through may occur if ..

A the current is too low

B the root face is too large
C the root gap is too large
D all of the above

I' 1\ ('ode of Practice is

A a standard for workmanship quality only

B a set of rules for manufucturing a specific product
C a specification for the finished product
D all of the above

l'.\'I North. Middkshrough 2

Welding Inspection: Multi-Choice Questions Paper 1 (Rev. 2)

.
Pica c return thi paper unmarked
I ti A solid inclusion in a weld may be .

A entrapped slag
B entrapped gas
(' lack of inter-run fusion
D all of the above

I7 Winch of the following is a planar imperfection?

A a lack of sidcwall fusion

B a slag inclusion
C linear porosity
D root concavity

IX hir fillet welds, it is nonnal practice in the UK & USA to measure .

A throat thickness
n leg lengths
C penetration depths
D both A& C

J 'l In a bend test, when the face of the specimen is in tension and root is in compression, the test is called ...

A a root bend
B a side bend
C a face bend
D a longitudinal bend

21l I leavy porosity on the surface of some MMA welds made on a constmction site is most likely to be caused by .....

A use of the wrong class of electrodes

B the use of excessive current
C moisture pick-up in the electrode covering
D a bad batch of electrodes

:.: I Slag mclusions may be present 111 ..

A manual metal arc welds

B metal inert gas welds
C submer d arc welds
D both A and C

,,., The main cause of undercut is

A excessive amps
B excessive volts
(· excessive trdvcl speed
D all of the above

2 1 Which group of welders is mos I likely 10 require continuous monitoring by u welding inspector?

A concrete shuttering welders

B ovcrlnnd pipeline wclde1~
(' tack welders
D maintenance welders

IWI Nrnth , Muhllcshrnugh _l

Welding Inspection: Multi-Choice Questions Paper 1 (Rev. 2)

...
:'4 Wl11ch of the following fillet welds is the strongest (assuming they are all made using the same material and
welded using the same WPS)?

A 8 mm throat of a mitre fillet

B 7 mm leg + 2 mm excess weld metal
C mitre fillet with IOmm leg
D concave fillet with 11 mm leg

:'"> A typical mcluded angle for MMA welding ofa full penetration pipe butt joint is

A 3'i"
B 70"
c 90°
D dependent on the pipe diameter

:'6 A fillet weld has an actual throat thickness of Smm and a leg length of 7mm. What is the excess weld metal?

A 2.lmm
R l.Smm
C 3. lmrn
D I .4mm

-:'7 The fusion boundary ofa fillet weld is ....

A the boundary between the weld metal and HAZ

B the boundary between individual weld runs
C the depth of root penetration
D the boundary between the HAZ and parent material

:'8 If a Welding Inspector detects a type of imperfection not allowed by the Application Standard he must always .....

A request further NOE

B reject the weld
C prepare a concession request
D only reject the weld if he considers it to be harmful

2<J BS EN 970 allows the use ofa magnifying glass for visual inspection but recommends that the magnification is ....

A x2
ll x2 to x5
C x5 to xlO
() not greater than x20

10 The nrnJonty of welder qualification tests are carried out using an unbacked joint. This is because .........

A it is quicker, and cheaper, if back-gouging is not required

B if the welding process is not TIG, back purging is not required
C all welder qualification tests are done on small diameter pipe
D it requires more skill and increases the welder's qualification range

!'WI North. M1ddlcshro11gh

' ' ..
Student Name Date
------- ----
Answers Sheet for Paper 1 Rev 2

1
2 --1------1-------1

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7
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T WI
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Vflf71e~~------------- THE WELDING INSTITUTE

Elemental)' Symbols as extracted from BS EN 22553

Number "' IUustration S bol

Butt weld bc twee plates with
-·.
A
raised edges. 1 Edge ged ·· r .

1 i} 'i weld. us~ .. e edges

being me~. · down completely :. ......
~··

2· Square Butt Weld

4 Single-bevel Butt Weld

S
, Single-V Butt W Id
With a Broad oot Face y
Single-bevel Butt Weld
6 With a Broa d Root F ce

Single-U Butt W Id
7 (Parallel or Sloping Sides)

10
Fillet Weld

Plug Weld; Plug

11 Slot Weld USA

~
12 Spot Weld

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TWI
l7f71.....________________ THE WELDING INSTITUTE

13 Seam Weld ()
••=r- L.

,;, __ :. \

Steep Fla It~ ina V Butt

1'4 Weld •. (Narrow Gap Preparation)

Steep- oke<l 'iogle-h vel Butt

15 W cltl. Nurrmv <lt1f1 PrP/lflrt1li1111)
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) 16 Edge\ eld
flC> III
11 Surfacm
~~
18 Surface Joint

19 Inclined joint
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20 Fold Joint
- -·-- --··· - ---~-------------'------------------~

)
~·
Supplementary Symbols Extracted from BS EN 22553
Shape of weld surface or weld Symbol

a) Flat (Usually finished flush)

___!!L Convex ~

c) Concave '-.-/

d) Toes shall be ~und smoothly ~

e) Permanent backing strip m
f) Removable backini? strip ~
IMR I.
.: '· .. ' {" - .~ ....·... .- ~
. • ' ~~ · 1 ' I

Welding Inspection of Steels WIS 5 •i&6

Sft:tioa 08 Weldiil~ SVblbOls" ,,... ~ · ,.•.,.•., · ·· · " ... ,.. , · "· 1 .. .. 0 • " · • • •

R v 09-0?-0 ( gh 2005 TWI UcJ

Welding Inspection: Multi-Choice Questions Paper 3 (Rev. 2)

"'
Which type of submerged arc welding flux is susceptible to moisture pick-up?

A neutral
B agglomerated
C fosed
£) they are all about the same

A large grain size, in the HAZ ofa C-Mn steel weld joint, may have.....

A low ductility
B low toughness
<· t11uh 111uuhlll,:m
IJ high tensile strength

A STRA test is used to measure .....

A the tensile strength of the welded joint

B the level of residual stress in butt joints
C the fracture toughness of the HAZ
D the through thickness ductility of a steel plate (the 'Z' direction)

,J The risk of hydrogen cracking is higher when MMA welding of ...

A C-Mn steels
B austenitic stainless steels
C low alloy steels for elevated temp.service
D low carbon steels for cryogenic service

~ The property of a material that has the greatest influence on welding distortion is the .....

A yield strength
l3 co-efficient of thermal expansion
C elastic modulus
D co-efficient of electrical conductivity

11 Which of the following is a suitable shielding gas for FC AW of stainless steels?

A 100% Argon
B 70% Argon + 30% He
C Argon + 5% Hydrogen
D Argon + 20% C0 2

The presence of iron sulphides in a weld bead may cause

A solidification cracking
B hydrogen cracking
C lamellar tearing
D weld decay

X i\ macro section is particularly good for showing.

A the HAZ microstructure

n overlap
C the weld metal microstructure
I> all of lhc aoovc

IWI North. Middlcshrough

~welding Inspection: Multi-Choice Questions Paper 3 (Rev. 2)

Please return this paper unmarked

..
" Wl11ch of the following procedures would be expected to produce the least distortion in I Smm straight butt weld?

A TIG weld single sided, multi-pass

B MMAweld single sided, multi-pass
c MMAweld double sided, multi-pass
D SAW weld I pass per side

111 ,\ suitable gas /gas mixture, for CiMAW of aluminium 1s ..

A 1011% C'0 1
B I 00% Argon
(· HO'~'u A1go11 I '.'.O'~ u ( '() 1
D 98% Argon + 2% 0 2

II Wl11ch of the following is associated with SAW more often than it is with MMA welds is?

A hydrogen cracking in the HAZ

B solidification cracking in the weld metal
C re-heat cracking during PWHT
D lamellar tearing

12 EN ISO 5817 (Level C) specifies that the limit for the diameter (0) of a single pore in a weld is: -
() S O :ls, but max.4mm where s =material thickness.
For which of the following situations is the pore acceptable?

A s = 20mm, measured pore diameter= S.Omm

B s = IS mm, measured pore diameter= 4.Smm
C s = I Omm, measured pore diameter= 3.0mm
D s = I Omm, measured pore diameter = 3. Smm

Ii l'o measure arc voltage accurately it is recommended that the voltmeter should be connected ....

A across the arc and as near as practical to the arc

B across the power source tem1inals prior to arc initiation
C across the power source tenninals during the welding operation
D all of the above are suitable

I ..J I .amcllar tearing has occurred in a steel fabrication. What technique could have been used to find it before the
weld was made ?

A X-ray examination
B liquid penetrant examination
C ultrasonic examination
D it could not have been found by any inspection method.

I" l'rc-ht!atmg a low alloy steel prior to welding is done to minimise the risk of ..

A porosity
B excessive distortion
C llAZ cracking
D lack of fusion

IWI Nmth. M1ddk.-shro11gh

Welding Inspection: Multi-Choice Questions Paper 3 (Rev. 2)

Please return this paper unmarked

...
I <1 l'yp1cal temperatures used for normalising a C-Mn steel plate are ....... .

A 600 to 650°C
B 1000 to 1100°c
C 100 to 800°C
D 880 to 920°C

17 hir GMAW the burn-off rate of the wire is directly related to .........

A the stick-out length

B wire feed spee<I
(· lho Ill\: vullngo
D the travel speed

18 For MMA welding of a 60111111 wall nozzle to a I OOmm wall vessel shell, pre-heat temperature should be checked .

A before welding starts/re-starts

B on the shell and the nozzle
C at points at least 7Smm from the joint edge
D all of the above

I' I A crack running along the centreline of a weld bead could be caused by ....

A use of damp tlux

B lack of preheat
C arc voltage being too high
D weld bead being too deep and very narrow

:'.O In order to improve resistance to service failure caused by cyclic loading, it is good practice to .......

A use low heal input welding

B use steel with a low CEV
C ensure there are no features that give high stress concentration
D all of the above

:'.I The use of low carbon austenitic stainless steels and stabilised stainless steels will minimise the risk of .......

A HAZ cracking
B weld decay
C weld metal cracking
D distortion

")'') Whrch type of SAW nux is susceptible to breaking down into fine particles during circulation?

A fu~;t:1J
B neutral
C alloyed
D agglomerated

2I The maximum hardness in the HAZ ofa steel will increase if the. .

A heat input is increased

B l'l'.V 1s increased
C joint thickness is decreased
U all of the above

TWI No1th, M1ddkshm11gh

'Welding Inspection: Multi-Choice Questions Paper 3 (Rev. 2)

2..i BS EN ISO 5817 (Level B) specifies the limit for Exce;s Weld Metal (h) on a butt weld
h ~ I mm + 0.1 b, but max. Smm, b = weld width.
111 which of the following situations is the measured Excess Weld Metal acceptable.

A b = lO measured excess weld metal= 2.5mm

13 b = 20 measured excess weld metal= 3.Smm
C b = 35 measured excess weld metal= 4.Smm
[) b = 45 measured excess weld metal= 5 5mm

..' ~ i\ car ho11 1111111g1111csc slt..'CI 1s hcmg wcl1k'tl hy MMA 11nd lhc clcclmdc ru11-oul-lc11gths that have been used are
11111ch shorlcr 1ha11 spec11ied by lhe Wl'S Th.is devi111ion may give

A an increased risk of hydrogen cracking

B an increased risk of solidification cracking
C lower values ofHAZ toughness
D higher values ofHAZ hardness

2<1 rhc first procedure that is prepared for a Weld Procedure Qualification test weld is a ........

A pWPS
B WPS
C WPQR
D WPAR

27 Transfer of material identification by hard stamping is sometimes not allowed for high integrity applications
because

A it is too slow
B it can be a safety hazard
C it may be damaging to the material
D all of the above

28 When welding thin plate, distortion can be minimised by ......

A using back-step welding

B minimising weld volume
C using bridge tacks
D all of the above

2" Which of1he following would be considered to be high Heat Input welding?

A 5 ::o J/111111
B 55 J/mm
c 5.5 J/mm
[) 5.0 kJ/111111

111 l111t1atmn ofa TIG arc by using a lligh Frequency spark may not be allowed because.

A it often causes tungsten inclusions

£3 ii CCIII damage electronic equipment
C it is an electrical safety hazard
D it often causes stop/start porosity

IWI Nmlh. Middlcshrough

·student Name Date
-------- ----
Answers Sheet for Paper 3 Rev 2
-- ------------------,---------,

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------4---------- - - - - - - -

21 1.'
---- ··-·- - ------+--------<
,,
22 II

--- ---
23 ···-- ------------
24 l ___·
--- ---··- - - - - - - - - - - + - - - - - - - ;

25 (
26 - -;y----· - ---- ---
-- -- - -- ---
c. -----------
27----- ------------
28
- .
'
------t---~- -------

29 ]·
- ---- - - - - - - - ----------
30
\Velding Inspection: Multi-Choice Questions Paper 4 (Rev. 2)

Which of these drawing symbols shows weld penetration depth in accordance with BS EN 22553?

""

A e""- ~~ IOs
-f-----
B
slO

~-------------
v
('
Ills y
~~------------

D - -- - -~~)- - - -
/
BS EN 288 is a specification for ..

A welder approval testing

B welding equipment calibration
C welding procedure approval
D consumables for submerged arc welding

What determines the penetrating power of Gamma rays?

A time
( t3 ) type of isotope
t,..
' IJ'
source-to-film distance
source strength

.J Which element has the greatest effect on the HAZ hardness of carbon-manganese steel?

A Molybdenum
B Chromium
C Titanium
'. D) Carbon

Pre-hcaiing a steel plate with a carbon equivalent value (CEV) of0.48 may be required in order to .....

A drive out moisture from the plate

( 13) prevent excessive hardening in the HAZ
~~· prevent the fonnation of carbides
h improve the mechanical properties of the weld metal

11 A welder approval certificate should be withdrawn if ........ .

A he has not done any welding for a period of 4 months

B he has been absent from work for a period of 7 months
C the repair rate for his welds exceeds 1%
D all of the above
\Velding Inspection: Multi-Choice Questions Paper 4 (Rev. 2)

7 In friction welding, the metal at the interface when the joining occurs is described as being in the ......... .

A liquid state
B inter-critical state
:·c-, plastic state
D elastic state

X t\ pcnetrameter is used to measure

A the size of a discontinuity in a weld joint

B the density of a radiographic film
C the degree of film contrast
r _l]J I he quality ol" I he radiographic technique

'I Wlr1d1 ol" tlrc followirrg cuttirrg rnclhods is suit11blc for cutting stainless steel?

A\ plasma
B oxy-acetylene
C oxy-propane
D all of the above

IO Which of the following would be classed as the most serious type of defect?

A a buried linear slag inclusion

R buried lack of inter-run fusion
C surface breaking lack of sidewall fusion
D surface porosity

I I Ultrasonic testing has an advantage over other NDT methods for the detection of ...

.A· : lack of sidewall fusion

B root undercut
(' incompletely filled groove
D root concavity

12 Exceeding the maximum inter-pass temperature specified for a C-Mn steel weld joint, may give

A excessive porosity
B burn through
<. C lower toughness
D all of the above

I I MIG/MAG welding has a tendency to give lack ofsidewall fusion when ....... .

A spray transfer conditions are used

B I00%C0 2 shielding gas is used
C pulsed current is used
'D: dip transfer conditions are used

1-1 The temperature range over which a steel goes from having high toughness to low toughness is called ....

A lhc c1itical transformation temperature

B the ductility dip temperature
(' the bi-modal temperature
(o·, the transition temperature

I \VI N,.,111 Mid1ll1••hrrn111h

Welding Inspection: Multi-Choice Questions Paper 4 (Rev. 2)

I.'i For SAW. what is the effect of raising arc voltage but keeping with all other parameters the same?

A the weld bead width wiH increase

B the depth of penetration will increase
C the weld bead width will decrease
D the depth of penetration will decrease

Ih Changing an essential variable (beyond the allowed limits) for a qualified welding procedure ....... .

A may change the mechanical properties of the joint

B may adversely affect the quality of the weld
C will require a new welding procedure to he approved
(). 1111 or the above

II W11 h 1clC1em.:c 111 lhc v111 ious g1udcs 111' sluinless steels. whid1 uf the following statements is true?

A they are all non-magnetic

B they all require I00% Ar for GMA W
C they all have very high thermal conductivity
D only certain grades can be used for service at very low temperatures

18 Which of the following AWS AS. I electrodes has a rutile covering ........ .

A E 6010
B E 7016
C' E 7018
D E 6013

19 Welds made with very high heat input will show a reduction in ...... .

A tensile ductility
B notch toughness
C fatigue strength
D creep resistance

20 During PWHT of a complex fabrication, it is heated to the soak temperature at a much higher rate than
specified by the procedure. This may ........ .

A cause excessive oxidation

B not allow sufficient time to relieve stresses
C introduce excessive compressive stresses
D cause distortion

21 When MAG welding in dip transfor mode (short-circuiting mode) spatter can be reduced by .......... .

A using inductance
B using 100% C02
C using Ar+ 30%1-fe
D increasing the stick-out length

.'.2 Repair welding of in-service plant and equipment may be more clitlicult than making repairs during initial
fohric11l ion because

A the material may be contaminated

LJ uccess 10 repair area may be Jillicult
C positional welding may be needed
D of any of the above

rwl Nnrih Mirlrllr~hrn11oh 1

Welding Inspection: Multi-Choice Questions Paper 4 (Rev. 2)

Please return this paper unmarked

21 for gamma radiography of a steel weld at 35mm thick, the recommended isotope is ......... .

A Thulium 170
B Ytterbium 169
C Iridium 192
D Cobalt 60

24 The sensitivity of a radiograph is assessed

A by using a densitometer
B' by using an image quality indicator ( IQI )
(' from the kV A used
D fro111 stand-off used

!' A l11111svc1se tensile lest, 1"1011111 Weld l11t1cetlu1e Approval RcconJ (WJIAR) test plate, is used tu measure

A the tensile strength of the weld

B the tensile strength of the joint
C the stress/strain characteristics of the weld
D the stress/strain characteristics of the joint

.~h The highest and lowest heat input positions are considered to be ......... .

A PB highest; PA lowest
B PE highest; PC lowest
C PD highest; PB lowest
D PF highest; PG lowest

27 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 -50°('? .

A rutile
B basic
C cellulosic
D choice will depend on the welding position

28 The dip transfer mode (or short-circuiting mode) of metal transfer used for MIG/MAG welding is
characterised by

A giving deep penetration

B being suitable for positional welding
C giving low spatter
D all of the above

Carbun c'i1.1ivalc111 values (CEV) are used to delcnnine the how to avoid the risk of ....... .

A hydrogen cracking
B lamellar tearing
C solidification cracking
D weld decay

w When 2 different 11111terial types arc welded together, the joint is reforred to as ....... .

A a composite joint
B a transition joint
(' an aulogcnous weld
D all of the ahove

l"W I Nnrt h Mi<irllP<hrrnooh 4

 Student Name Date
------- ----
Answers Sheet for Paper 4 Rev 2
------ - - - - - - , - - - - - - - ,

1 ----·· ------------ ------

2 ---·>-----+-----;

3------ -------·<-----•
4 ··-- ---------·-r----·-··-- -
5
6
7
8
9 - - -- - - - - - - - - - t - - - - - - - - f

.
10
---- - ~-----+---------;

11
- -
12 - ------i---------+-------1

13 --- ---~-i-----·-·---t----;

14 ---------------.-----
- ------ --

15 -- --- ·----~--·------1-----

16 -----+-----1------;

17 - ·----- ---------~---

18
19----- ---· --------~

20
--- ···-···· ---------------t---------

21-- --- -- --------+-----i

22- ·---·- - - - - - - r - - - - -
23
- ------ -·-----------+------
24
-- .. ----- -·--------r------------

---
25 ---- - - - - - ; - - - - - - - - ;

26- f - - - - + - - - - - - - 1
27
28 ----t-----~ ----~

29 - ------- --- - - - · - - - ---·-------

30 ----~ ---------
 WELDING INSPECTION STEELS- COURSE REF. WIS 5

END OF COURSE MULTIPLE CHOICE PAPER (MCQ.002)

1. 13S499 Part II communicates by the use of symbols the type of joint preparat10n to
be used. Listed below are four sy~ols: wllich of these indicates the depth of
penetration of a weld required on the joint.

1'I

~nL(_.____
/
f ',

jf( 10f~

r -t""'"
(' 10
10 ·

2.. Which of the following symbols would indicate that the weld has to be finished
flush on the "other" side of the weld.

13 \/
,/ -·y:;···-·--
~

[) {--d_?--
3. What two functions in arc welding must be in equilibrium to enable a stable arc to
be established.

A Arc voltage.
U Current.
C Wire/electrode feed rate.
D. Metal burn-off rate.

4. In MMA welding, what parameter is used for the control of penetration into the
base material.

A Voltage.
f) Welding speed.
C. Iron powders in the coating.
U. Currt:;r 1t.
 5. In the welding of a butt joint made from one side, which of the foll owing contrcfr.>
the profile of the root bead.

A Root face.
B. Bevel angle.
C. Root gap.
D. None of the above . .. . · '"

A.
B.
C.
D.
.,.
I. Which one of the following destructive tests would indicate the toughness of weld
metal, parent metal - HAZ. .·., ·.

/\. Macro.
f3 Nick break. ' ·
·.-·. --• ,.;.
C. Hard ness. , ~~ 1~ ::;.· ;:
D. Charpy Vee notc~.:'-. }}fr ' · ·

9. \Vhich of the following chemieal elements has the greater effect on the
hardenabiiity of a steel plate;< ·

/\ Molybdenum .
B. Chromium.
C. Titanium.
II <-:arbon.

10. In MAG/C02 welding, which parameters give the greatest control of weld
appearance during dip transfer or short circuit welding.

() /\. Wire stick-out length. . ,

L3. Amperage. · ~~-~ ..-;'. ·. .. ; . ·.. , ;:: . ..
C. Wire feed speed , ~::~:--\.;· ·. : _: ,·;-.: ·.;':':7t<- :·: . .
D. Ind ucta nee. · '_ ...{· (.',i:_. ';~.: ·: <l-:-:~i:~·: ".9 ::;.~~~i ~-> ._ . .
11. In MMA welding, the !ag prOduced can· .. ri d t it th welding position:
which type of slag would be required
,, .; .
for .
:
welding in the HV position.
' ····.
. •.·- ~

/\. Fluid .
n. Viscous.
. '\
C. None or the above . . · ·
D. Semi Fluid.
 ~ 2. The weld 1-;ietal deposit of manual rnetal arc ele;ctrode achieves it mechanical
strength through.

A. The core wire.

B. T~e flux coating.
C. Iron powders with the flux coatings.
o. None of the above. · "'
/ ';
- ;-' ":: . ~ 1 ... -.
· ;_ ;:-;- v
:'·'. .)~ ·.;; .
/ ..~: .·
,,.t.-:~:
, ...:_.~ .
• ..

14.

A. Ductility. . . : · ·,: :-·

B. Toughness.~ ~''.-h~4:~~;:;~~-~~k';,: :. : :·<~~--i, ~
c. Fatigue strengtJn:::; : :·; ·t;j. :. ;.- ;
o. Mechanical strength.'+~'~- ·
--t-;~_ ·- . ·- ~ . ·.·._ ·· ~~r ~ r ·
·· · :. ~ ~-: >
..
:
15. In the welding of aus·te~nitic'pip~work, the bore is usually purged with A~ to.
' .·_.
• - I
' . ·"'
: . ' .

A. Prevent formation of porosity in the weld.

B. . Prevent bum-through ·the root run. ·in
C. Prevent oxidation of the root bead.
D. Eliminate the formation of H2

16. I n X-ray work the quality of the radiographic negative is assessed by the.

A Density of the film.

) B. IQI Indicator. ·. :;
C. KVA available_~ ;-~. · ·:_:·:·'· 1·:· .·- ..~ .- · .. ·
D. Stand-off distance . ..:.:<·:·.:· ., - ~

.... ·...... ,

17. A steel described as QT will have improved tensile properties be use it has .
. ·. .. ·. r;~:::.·. , ..

A. Had control of chemical composition.

B. Been heat-trea!~-: .~:~.:'
c. Been quality tested . .:::··-...
O. Been vacuum- .··foetted. , .·•
.
·.

· .~··_·- · ·
.
. . ...
'/ ....

·,
 1B .

A.
B.
C.
D.

19. In sub.

A. ;.
B. • ".\; ·~ ~L: ,.
C. ·. ..
' ' . 41., ;

D.

20.

(~ \ Hydrogen control is needed.

B. Iron powd rs in ·the ~ele.Ctrode. -~ .• ..
C. Higher arc voltag-e-,,ca~be-obtalned.
D.

21.

. '
A. .-
B.

D.

22.
--·- ;; ... : .•
A. Sintered and agitated_.,' ;~ :/;:· :-
B. A it.a d d fu ed -·- . . . ;C_ ,,r . '.r-~ ··

C.
D.
C~s~:d ~~d a:Q1o~e~;~A(
Fused and a ··\ ~ ~-·.:.i ..~.. .•. .
' .~~~~ir, :;-,;,p~:i:N :.;L
l~~._;:;;!'t ~ -~.·: . •. ;. •.-:•.'.- .....~. -~'-· .. .·

. i
. . .· ' ( '..~'.:~·tt,.?J,~~~\.;:'fj}d}.f~.< . . : . · ~_-. . ~f;~~~ ;<;~;>~:,;J.:~i~t.~<:: '
23. In a steel which has improved CfOOP properties at.elevated temperature; which
one of the following elenie.rits· ~elps improve this? · :-~--.;.~,~" · : · '· · · :_, ·:~"r"·'· ·
... •
I ;0., • :

. ;
·. ·: _.
"'
:<-~
...
.
't • •

·. \ A. Tungsten.
·.'·
.. - .....~ . ·. B. Mang .n _,
•• ~ _J
C.
D.
Molybdenum.
Carbon.
.
-

'·
 24. Welding a steel plate of CE of .45 would require preheating to?

A.
B.
C.
D.
,.., r:
/.. J.

·. ' A.
·,, B.
. . C.
D.
._::: ~ . .···.
2G.

C.·

21•.

A.
B.
C.
D.
., .: .... . . ·- · ··
...: .. ·._.... .:;__(_f. _<i ·-: · ; •.· : .
28. In a tensile test, a brittle material would be indicated if the fracture surface?
·. .
~: : ·
-~ • . • • :-. • ~ ~. 'I.';. ••

A. Shows a reduction in size. · · ·- ,',~i_':_:_.

B. Is flat and fe:atureless;,. ._ .. ;;.-::·:..,_ . . ,
C. Breaks in the welchnetal. . < :f:.. ~.:· ,: .
D. Breaks in the p ,.· · . . , ,.~ ~ : L·:~~;::.e~.
· . ;·-:J¥i?-~&i .-. ~~ i~ .. , . ;- .. .. . -. _:.-:"~b~~>~;~:~~i;~~ii1~~~;r
be'.r...'required _in:~~~:~.~
. test would
29. What destructive· to ascertain the likelihoo(f .o.f::·:cracking
. . • .•
the HAZ of a wel .!.6-U ,
d:~ :.~ ·: ~ :.:.'..,.
-¥.1.1r--.~ .. ~::. ·a:, ' ._ _,_,,,. ··. · ··
-~ --' . _. :
· ··: . . · '· ...;...
~..
·· .,.. :.' ..;' ~. ·.·•.: · .-~;-'.·.. ; : ,
~; ··~,. ~ , -~·- -;· <::i( ~ :· _ ·

A
B.
Nick br~~Jll~Iii~1jh~J.
Side: bend test.~ -::·· :j>~~-::-: · : · ·· ~ · ··
· •.··•. ·_. ..,~-?' · · ' ·-. ·
... .• ; • • ... . :'." ;1--:-: ·."'6, ' ·.
~: •• · ~.
. ,, : .
C. Charpy impact ·->~~~:.. ': .. _.

.·'
D. test.~;~-'..· ~~"- ,;; ...· ..
Macro
~ -·
..
-. . .
30. In submerged arc Ylelding/~xcessive arc voltage may cause. . .
, .·.;...--=·< ·,,
. ..·, _ -~

· . ·· .-: .::s:i' ·.-~ ::· ·>-r~£ > · ·

A. Excessive penetration'. .
B. Change in weld corn.position.
C. Narrow weld width: -·
D. Excessive bead profile.
 .-.

ANSWER SHEET FOR MCQ.OOL

NAME: _ _ _ _ _ _ _ _ __
..... ··-,.:--, ·
.· OJ.l~~J!ON
·~N .. , •.
0 . ....

1-
7
l
I 8

/. .. ,,
, .. r .1
.
. ·; ,,
'

12 B
13 c 28
14 lb D ..
:1__~__ L___ c____.__ _ - - . L_ _ 3o___...___8_ ___._____.;·~-~
( _) ·; ._ ,
:_=·· - ~ ~

>.
·'

'·

"" "'-.":.
·--
 WELDING INSPECTION STEELS - COURSE REF. WIS 5

MULTIPLE CHOICE QUESTION PAPER (MCQ.001)

Answer all questions.

1. When "hydrogen control" is specified for manual metal arc welding project the
electrode will normally be:

A Cellulosic.
B. Iron oxide.
c Acid.
0 Basic.

2. You would with certainty recogn~se a l1ydrogen ;:2Q![;olle9_ flux covered electrode
from its:

A Colour.
G Length.
C. Trade name.
/D) AWS/BS639 Code Letter.

3. When manual metal arc welding is being carried out on an open constructic;. site,
which group of welders are the most likely to require continuous monitoring.

A Concrete shuttering welding teams.

B. Pipe welding team.
C. Plater welders.
D. Plant maintenance welders.

4. You notice manual metal arc electrodes, stripped of flux, are being used as filler
ob~ because:
wire, for TIG welding. You would _.., ~

A It is too expensive.
B. The wire would be too thick
C. The weld metal composition may be wrong.
D. The wire is too soft

5. When open site working, serious porosity in metal arc welding is brought to your
attention. What would you investigate: ·

A Electrode type.
B. Power plant type.
C. Electrode stor.age.
D. Day temperatu~e.
 G. Tl1e steel cornpos1t1on ma structural contract changed from 0.15% carbon, 0 (-)';-;,
rnanqane~;e, to 0.2% carbon, 1.2% manganese. MigM this influence the 1nc:1dcrm ·
of

A f.Joros1ty
8. Cracking in the weld area. ,.,
C Undercut for fillet welds.
O Lack of root fusion defects.

7. One of the following alloys is non-magnetic. Which?

!<. 4.0% Chromium molybdenum.

fl 12% Chromium.
C Austenitic Stainless Steel.
U ~10% N1d~cl Steel

H When TIG welding Austenitic stainless steel pipe. Argon gas backing is called for
This 1s to:

t_._ Prever.t oxidation.

8. Prevent underbead cracking,
C Prevent porosity.
0 Control the penetration bead shape.

0 Pre-heating a Carbon steel manual metal arc welding is carried out to minimise
the risk of:

1\ Scattered porosity.
H. Worm hole porosity.
C Parent metal cracking.
D. Lack of penetr2tion.

10. In UK practice BS 499 Part 2 specifies that the drawing dimension quoted for a
fillet weld is the:

A Leg length.
B. Actual throat thickness
C. Weld width.
D. None of the above.

11. For open site manual metal arc welding the following equipment is available.
Whi.J1 woul<l you choose for safe working.

A Single operator transformer.

B. Multi operator transformers.
C. AC/DC composite power unit
D. Diesel engine driven motor generator.
/. 12. If subrncr~]ccl arc wcld111g 1s to be used to make butt welds. which would you be
most cnt1cal of

/\ The root gap tolerance.

l} The angle of preparation. ,.,
C Tt1c root face width.
D. The gas cut finish.

13. During C02 welding, the arc length is most likely to be affected by:

A The wire diameter.

l3. The current return connections.
C The gas flow rate.
D The torch to work angle.

14. Pre~1eat1ng for arc welding applies to:

f:i._ Assembly welding only.

fl Assembly and tack welding.
(_~ Joints o';er 25rnm thick only.
U Cruciform welds only.

15. You see a welder using 0>~y-acetylene flame with a long feather~d inna.; r::ane.
Wt1at would be the effect of this on a carbon steel.

/\ The weld could be hard and brittle.

G The weld metal could be too soft.
C. There will be no effect on the weld.
D The weld will have undercut.

I G. A welder qualification test is to verify:

/i, The skill of the welder.

B. The quality of the materials.
C. The non-destructive test procedures.
O The manufacturing m.ethods.

17. A fabricating procedure calls for fillet welds to be Mblended in" by grmding. This is
to influence:

A H.AZ. cracking.
B. Fatigue life.
C. Rc::;idu.al str.:;:£;;,,.
O Yield strength.

18. Bend test specimens have been taken from a 25mm thick carbon steel butt weld.
Which would show lack of inter-run fusion:

A Side bend.
f3. Root bend.
C. Face bend.
D. Guided bend.
1 ~- Larnellar tearing has occurred in a steel fabrication. BEFORE welding could 1t
t1ave been found by:

A X-ray examination.
[:3 Dye penetrant.
c Ultrasonic inspection. "'
D. It would not have been found by any inspection method.

20. You are to oversee the arc welding of some machined fittings and find they are
cadmium plated. Would you:

/\ Penrnt to proceed.
f) Permit it to proceed with fume extraction.
c: Stop the operation at once.
u /',dv1se the we!cer to driri:; milk 2nd proceed.
 ANSWER SHEET FOR MCQ.001

NAME: _ _ _ _ _ _ __ DATE- - - -
-----··------·-
QUESTION ,. A-N-SWERr QUESTION ANSWER
I

i
No '* No I --
i . ~~- -~--------,--!D I 11 D I
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----

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--Tc
--- TB
------

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-- -
-·-

- -- .. ---
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I
I
. -----·- --,--I 15
16
A
A
g
I
I
!
I
---------- -
--------

jc I I 17 I
I
I

- - - - -- -
8 iA _______J_ I 18 p, I I
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-
9 !c
---------------·
19 D
10 I A
-·---------·---··-··- -~--~-----'------
20 c.
 WELDING INSPECTION STEELS - COURSE REF. WIS 5

MULTIPLE CHOICE QUESTION PAPER (MCQ.001)

Name: ,.,

Answer all questions.

1. When "hydrogen control" is specified for manual met:al arc welding project the
electrode will normally be:

A Cellulosic.
B. Iron oxide.
C. Acid.
D. Basic.

2. You would with certainty recognise a hydrogen controlled flux covered electrode
from its:

A Colour.
B. Length.
C Trade name.
D. AWS/88639 Code Letter.

3. When manual metal arc welding is being carried out on an open ~onstruction site,
which group of welders are the most likely to require continuous monitoring.

A Concrete shuttering welding teams.

B.1 Pipe welding team.
C. Plater welders.
0 Plant maintenance welders.

4. You notice manual metal arc electrodes, stripped of flux, are being used as filler
wire, for TIG welding. You would object because:

A. It is too expensive.
B. The wire would be too thick
:C The weld metal composition may be wrong.
D. The wire is too soft.

5. When open site working, serious porosity in metal arc welding is brought to your
attention. What would you investigate:

A Electrode type.
B. Power plant type.
C. 1 Electrode storage.
D. Day temperature.
6. The steel composition in a structural contract changed from 0.15% carbon, 0.6%
manganese. to 0.2% carbon, 1.2% manganese. Might this influence the incidence
of: ,.,

A Porosity.
B. Cracking in the weld area.
C. Undercut for fillet welds.
D. Lack of root fusion defects.

7. One of the following alloys is non-magnetic. Which?

A 4.0% Chromium molybdenum.

B. 12% Chromium.
C. Austenitic Stainless Steel.
D 9.0% Nickel Steel.

When TIG welding Austenitic stainless steel pipe, Argon gas backing is called for.
This is to:

A Prevent oxidation.
B. Prevent underbead cracking.
C Prevent porosity.
D. Control the penetration bead shape.

9. Pre-heating a Carbon steel manual metal arc welding is carried out to minimise
the risk of:

A Scattered porosity.
B. Worm hole porosity.
C.· Parent metal cracking.
D. Lack of penetration.

10. In UK practice BS 499 Part 2 specifies that the drawing dimension quoted for a
fillet weld is the:

A Leg length.
B. Actual throat thickness
C. Weld width.
D. None of the t:1bOY.$.

11. For open site manual metal arc welding the following equipment is available.
Which would you choose for safe working:

A Single operator transformer.

B. Multi operator transformers.
C. AC/DC composite power unit.
o.: Diesel engine driven motor generator.
12. If submerged arc welding is to be used to make butt welds, which would you be
most critical of:

A.'- The root gap tolerance.

B. The angle of preparation.
C. The root face width.
D. The gas cut finish.

13. During C02 welding, the arc length is most likely to be affected by:

A The wire diameter.

, 8~1 The current return connections.
C. The gas flow rate.
D. The torch to work angle~

14. Preheating for arc welding applies to:

A. Assembly welding only.

B. Assembly and tack welding.
C~ · Joints over 25mm thick only.
D. Cruciform welds only.

15. You see a welder using oxy-acetylene flame with a long feathered ·inner cone.
What would be the effect of this on a carbon steel.

1A. ·, The weld could be hard and brittle.

B. The weld metal could be too soft.
C. There will be no effect on the weld.
D. The weld will have undercut.

16. A welder qualification test is to verify:

1A.j The skill of the welder.

1r The quality of the materials.
C. The non-destructive test procedures.
D. The manufacturing methods.

17. A fabricating procedure calls for fillet welds to be "blended in" by grinding. This is
to influence:

A H.A.Z. cracking.
B: Fatigue life.
C. Residual stress.
D. Yield strength.

18. Bend test specimens have been taken from a 25mm thick carbon steel butt weld.
Which would show lack of inter-run fusion:

.A.'1 Side bend.

B. Root bend.
C. Face bend.
D. Guided bend.
19. Lamellar tearing has occurred in a steel fabrication. BEFORE welding could it
have been found by:

A. X-ray examination. "'

B. Dye penetrant.
C. Ultrasonic inspection.
D. 1 It would not have been found by any inspection method.

20. You are to oversee the arc welding of some machined fittings and find they are
cadmium plated. Would you:

A. Permit to proceed.
B. Permit it to proceed with fume extraction.
C. Stop the operation at once.
D. Advise the welder to drink milk and proceed.
 ...... ~--;~···..;'-···

Welding Inspection.

General Theory (Multi-choice) Paper WI - 1

Name:

Date: .. J.L ./.t ./.2a~.6. ............ .

i
L.

f11structions. Using a PEN please circle the letter next to your chosen answer.

I. Which of the following best describes the duty of a welding inspect9r ?

a. To carry out inspection and NOT in order to find weld defects.

, b) To attempt to ensure that all welding and any associated actions are carried out
in accordance with the agreed specification.
c. To carry out welding inspection and radiographic interpretation in accordance with the
agreed procedures for the work being carried out.
d. To ensure that all welds which undergo inspection are free of defects.

Which of the following butt weld preparations is usually the most susceptible to lack of
side wall jiJsion during the manual metal arc process?

la~ A double U butt weld.

' )

h. A single V butt weld.

c. A double V butt weld.
d. Lack of side wall fusion is not a problem with MMA welding.

'. What is the leg length of a fillet weld ?

a. The distance from the toe to the face.

b. The distance from the root to the face centre.
c.i The distance from toe to root.
d. The distance from the toe to toe.

,) What is the throat thickness of a mitre fillet weld with equal leg lengths?

a. The distance from the toe to the face.

, b) The distance from the root to the face centre. ·
c. The distance from the root to the toe
d. The distance from toe to toe

Paper ed/W I - I <:: I of 6

 .:; What is the ratio between the leg length and the throat thickness on a mitre fillet weld
with equal leg lengths?

a. I: I
b. 2: I
1C. 1.4)4:)
d. Depends on the fillet weld dimensions and joint fit up.

h l .ap joints contain:

,.
: a.I Fillet welds
h. Corner joints
c. Butt welds
d Single bevel hutt wr~lch

..)
·1 . \, I l l ·.. i ! '" L' ! \ l; I J ~~ j ) I.._~ J I I l J l c ~I 11 'I \ l ·~ l Ll t '

\.veld .....

a. . ..... must always be dressed to reduce stress raisers ..

h. . ...... must always overlap onto the external surface of the plate or pipe by at
least l .5mm.. ·
c. . ....... must always be checked by NOT'
d. . ....... none of the above can be selected as the specification requirements arc
unknown''

8. A duty not normally undertaken by a welding inspector is to:

a. Check the condition of the consumables

b. Check the bevel angle for damage
(c) Measure residual stress
cl. Measure pre-heat temperatures

L1 \Vhat action should the welding inspector take if arc strikes arc found adjacent to the
\\Ckl on a high tensile strength material(thc specification does not reference arc strikes)

a. Have the \veld and adjacent parent material removed

,,b) Report the presence of arc strikes.
c. ·\ccept the weld
d. Have the welder re-qualified

l 0. What is another term for suckback?

' ';\
a. Concave root
b. Root piping
c. Incomplete filled groove
d. Slag inclusions benveen the root run and hot pass

Papered/WI - I !: 2 of 6

II
 1 I. What is a crater pipe?

a. Another term for concave root

b. Another term for a bum through
...
c. A type of gas pore found in the weld crater
@> A shrinkage defect which may be found in a weld crater.

l :2. Which of the following is true for none planar defects found in a weld?

a. They are always acceptable

b. If found breaking the surface, removal of the entire weld is necessary
(0 They are not usually as significant as planar defects
d. They can only be detected by radiography

l .~. Cold lap is another term for:

l~ Lack of fusion at the toes of excess weld metal

b. Undercut at the toe of a weld
c. Lack of root penetration
d. Incomplete filled groove

14. Under most conditions which of the following welding positions .will deposit the most
weld metal? ~-

a. PG
b. HL045
C. PF
0) PA
I ·" How many temperature indicating crayons would be required to ensure that a
pre-heat temperature was within a specified range?

a. One
\"- _
ri:,-,
_,, Two
c. Three
d. As many as possible

I <i [:; it Frmi::..sibk tu allvw a single V butt \H:ld to II

a. It depends on the welder

<b'
' ,) It depends on the specification/procedure
c. It depends on the welding inspector
d. No, all welds should be completed before being allowed to cool

Paper cd/WI - I "C

I II
 I -; . Why is the arc shielded when using an arc welding process?

a. To eliminate hydrogen from the region of the arc

b. To retard the coolin~ rate of the weld
(~) To exclude the atmosphere from the region of the arc
d. All of the above

1S Which of the following will be the most affected when varying the arc length using
the MMA welding process?

,1:, Voltage
h. Amperage
c. Polarity
d. Travel speed

J ll What is the possible result if the amperage is too low during the welding of the
root pass using the MMA welding process?

a. Incomplete root penetration

b. Lack of root fusion
c. Electrode sticking/stumble
~) All of the above

2r1 \Vhat is the Heat Affected Zone (HAZ)?

a. It is the melted portion of the parent material

C~) It is the area adjacent to the weld metal which has undergone
microstructural change
c. It is the weld area plus the parent material which has undergone
microstructural change
d. It is the area of lowest tensile strength in the weld region

~ I A crater crack may also be described as:

a. Cold crack
b. Tearing i

cp ~~~~[~~:~~~lk
Which of the follo\.ving BSEN standards provides guidance on the visual
examination of fusion welds?

a. BS EN 910
b. BS EN 719
1'SJ BS EN 970
d. BS EN 499

Paper ed/WJ - I <;; 4 of.:,

IV
 n. The shear strength of a fillet weld is governed by:

a. The leg length

b. The weld face ,.
~J The throat thickness
d. The weld zone

'"1 /\.ccording to BS 499 - l what is meant by the term weldjzmction?

a. The area containing the weld metal and HAZ

b. The weld metal and parent metal
1 c.\ The boundary between the fusion zone and the HAZ
·cl'. The area which undergoes metallurgical change

Concave root may be caused by which of the following:

(~) Excessive back purge pressure or excessive root grinding

b. Excessive back purge pressure and entrapped gas
c. Excessive heat inputs or too small a root face
d. Excessive heat inputs and high travel speeds

~Ii A welder qualified in the PG position would normally be qualified for welding:

All pipe diameters

All welding positions
PG only
Any pipe/plate thickness

.'.7. What is meant by the term Code of Practice?

a. A document that provides guidance on auditing

b. A check list
(C) A documents which recommends practices and procedures
d. A standard for standardisation

::18. Which of the following defects is most likely to be caused by poor welding
technique when using the MMA process?

a. Hydmgen Induced C0ld Crncking

(}?) Crater cracks
c. Plate laminations
cl. Copper inclusions

Paper cd/WI - I Q

\'
29. A fillet weld with equal leg lengths of l 5mm and a throat thickness measurement
of9mm would have what type of profile?

@) Concave
b. Convex
c. Mitre
d. None of the above

-;n. \Vhat is meant by the term Specification?

a. A written description of all essential parameters & precautions

to be observed
b. Document established by consensus and approved by a
recognised body
A document that prescribes the requirements with which the
product or service has to conform
d. A written description of the precise steps to be followed
r.
,/ \

<_

)_. I

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