Welding Inspector
Name: Company:
Date:
1- Tick or indicate all the correct answers for the following:
I. If the amperage were too loo during root bead welding the
possible result would be:
a) Lack of penetration
b) Lack of fusion
c) The freezing of the electrode
d) All of above
II. Stress acting in the opposite direction of compressive stress is
known as:
a) Residual stress
b) Shear stress
c)Hoop stress
d) Tensile stress
III. Distortion may be affected by:
a) Restraint
b) Heat - input
c) Material properties
d) Material thickness
e) All of the above
IV. What is a crater pipe?
a) An oval tube
b) Another term for burn through
c) A type of porosity
d) A shrinkage defect
V. What is the purpose of a tensile test?
a) To assess tensile strength
b) To assess ductility
c) To assess yield strength
d) All of the above could be assessed
VI. Which electrodes are very susceptible to causing porosity in the
deposited welds if long arc employed?
a) Basic
b) Cellulosic
c) Rutile
d) None of the above
VII. Which of the following welding processes is most susceptible to
lack of fusion?
a) Submerged arc
b) CO2 (metal active gas)
c) Manual metal arc
d) Tungsten inert gas
VIII. Flame cut preparations may, during welding, increase the
likelihood of:
a) Cracking
b) Misalignment problems
c) Inclusions
d) All of the above
IX. Overlap in welds could be influenced by:
a) Poor welding technique
b) Welding Process
c) Welding Position
d) All of the above
X. The planar defect is:
a) Incomplete fusion defects
b) Slag inclusion
c) Incomplete penetration
d) Both a & c
XI. Undercut principally caused by:
a) Excessive amps
b) Excessive volts
c) Excessive travel speed
d) All of the above
XII. You noticed a very “veed” ripple shape. This is most likely
caused by:
a) Poor consumable choice
b) Welding position
c) Excessive travel speed
d) All of the above
2- What are the following standards stand for:
- SAEP-352 Welding Procedure Review and Approval
- SAES-W-016 Welding of Special Corrosion-Resistant Materials
- ASME SEC V Nondestructive Examination
- AWS A2.4 Standard Welding Symbols
3- Complete the following statements:
- All WPSs & PQRs shall conform to the latest edition of .........the
ASME SEC IX.........
- The maximum weekly repair rate for each welder on a linear basis
should not exceed.....0.2%...... and on joint basis, it should not
exceed .......5%.......
- The internal misalignment of butt joints shall not exceed.....1.5
mm........
- The maximum allowable SMAW electrode size that can be used is
..........(5mm for the 1G/1F position, 4 mm for all other positions) for
low hydrogen electrodes – and 5 mm for all positions in non-low
hydrogen electrodes..........
- A minimum of ........1.5 mm...... depth shall be removed by grinding
or machining from thermally cut or gouged surfaces of air
hardenable materials.
- Adjacent beads of a weld shall be ......staggered and not started in
the same location......
- The back purge for stainless steel and nickel alloys shall reduce
the oxygen level below ...0.05%......
- Inspection of welds shall include a band of the base metal at least
....25 mm.....wide on each side of the weld.
- Prior to use low hydrogen electrodes to A5.5, it shall be dried at
......370-430 °C........ for 2 hours minimum unless the electrodes
are supplied in dried conditions.
- Prior to use low hydrogen electrodes to A5.1, it shall be dried at
......260-430 °C........ for 2 hours minimum unless the electrodes
are supplied in dried conditions.
- The minimum distance (circumferential offset) between
longitudinal welds (including spiral weld seams) of adjacent pipe
joints shall be ........100 mm.......
4- For short circuit transfer mode processes, What is the meaning of the
following:
- STT : Surface Tension Transfer
- RMD: Regulated Metal Deposition
5- What is the difference between NDT & DT? Give examples for both of
them?
6- What are the three potential sources of Hydrogen encountered during
SMAW process? Answer: Moisture in the metal and electrode
coating, oil, elemental Hydrogen in the base metal.
7- What are several likely causes of porosity in carbon steel welds using
SMAW process? Answer: Poor welding technique and equipment,
excessive wind, moisture & weld contaminants.
8- What dimension is measured to determine the size of a concave fillet
weld? Answer: Throat.
9- Where would cracking most likely occur from excessive current input
in a single pass weld? Answer: Centerline of the weld.
10- Using GTAW process, describe what happens to a weld without
proper purging/back gassing on SS material? Answer: Oxidation at
the ID (Sugaring)
11- What is the meaning of HIC? And what are the different factors
that cause HIC? Answer: Hydrogen Induced Cracking, the factors
are: A sensitive microstructure, A sufficient level of hydrogen, A high
level of stress.
12- If welder qualified in 3G position in pipes, can he weld all
position? Answer: 3G position in pipe not mentioned in ASME Sec IX
