Welding Inspector Level 2: Multiple Choice Questions

Paper 2 - MSR-WI-2a

Name: ………………………………………………………….. Date: ……………………

1 Lack of sidewall fusion:

a Is the most susceptible in double U butt welds.

b Is never found in single V butt welds.
c Is the most susceptible in double V butt welds.
d It is not normally a defect associated with the MMA welding process.

2 Leg length of a fillet weld is:

a The distance from the toe to face.

b The distance from the root to face centre.
c The distance from the root to the toe.
d It’s 0.7 of the design throat thickness.

3 Throat thickness of a fillet weld (equal leg lengths) is:

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.

4 Compound welds:

a Always contain full penetration butt welds.

b Joints which have combinations of welds made by different welding
processes.
c Combinations between two different weld types.
d All of the above.

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

a Check the condition of the parent material.

b Check the condition of the consumables.
c Measure residual stress.
d Check calibration certificates.

6 Crater pipe:

a Is another term for concave root.

b Is another term given for a burn through.
c Is a type of gas pore, found in the weld crater.
d Is a shrinkage defect, found in the weld crater.

7 Fillet welds:

a The strength is primarily controlled by the leg length.

b The strength is primarily controlled by the design throat thickness.
c The strength is primarily controlled by the actual throat thickness.
d Both a and b.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-1 Copyright © TWI Ltd
8 Non planar defects:

a Are always repaired.

b Their existence will result in the removal of the entire weld.
c They are not usually as significant as planar defects.
d They can only be detected using radiography.

9 Welding Inspectors:

a Should measure voltage as close to the welding arc as possible.

b Should measure voltage anywhere along the welding cable.
c Should always take the voltage reading from the voltmeter on the welding
plant.
d Don’t normally take voltage readings, this is normally conducted by the
welder.

10 Welding inspectors:

a Normally supervise welders.

b Are normally requested to write welding procedures.
c Are sometimes requested to qualify welders.
d All of the above.

11 Burn through:

a Maybe caused by the root gap being too small.

b Maybe caused by the travel speed being too fast.
c Maybe caused by the welding current being too high.
d All of the above.

12 In an arc welding process, which of the following is the correct term used for the
amount of weld metal deposited per minute?

a Filling rate.
b Deposition rate.
c Weld deposition.
d Weld duty cycle.

13 When carrying out visual inspection from this list, which defect is most likely to be
missed?

a Linear misalignment.
b Cap undercut.
c Clustered porosity.
d Cold lap.

14 The throat thickness of 19mm fillet weld is?

a 27.5mm.
b 24mm.
c 13.3mm.
d 12.5mm.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-2 Copyright © TWI Ltd
15 Pre-heat for steel will increase if:

a The material thickness reduces.

b Faster welding speeds.
c The use of a larger welding electrode.
d A reduction in carbon content in the parent material.

16 Which of the following butt weld preparations is most likely to be considered for the
welding of a 6mm thick plate?

a Double V butt.
b Asymmetrical double V butt.
c Single U butt.
d Single V butt.

17 A welding inspectors main attributes include:

a Knowledge.
b Honesty and integrity.
c Good communicator.
d All of the above.

18 What is the maximum allowable linear misalignment for 8mm material if the code
states the following, ‘Linear misalignment is permissible if the maximum dimension
does not exceed 10% of t up to a maximum of 2mm’?

a 0.8mm.
b 2mm.
c 8mm.
d None of the above, insufficient information provided.

19 When conducting a visual inspection on a butt weld you notice an excessive

chevron shaped cap ripple. This may indicate which of the following?

a Incorrect electrode.
b Excessive travel speed.
c Incorrect pre-heat applied.
d That the welding has been carried out in the PF welding position.

20 Toe blending is generally carried out:

a To reduce the possibility of fatigue failure.

b To improve the toughness of the welded joint.
c To increase the Ultimate Tensile Strength of the welded joint.
d All of the above.

21 Arc strikes:

a When associated with a welded joint may lead to hardening of the parent
material.
b When associated with a welded joint may lead to cracking.
c When associated with a welded joint may cause a reduction in parent
material thickness.
d All of the above.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-3 Copyright © TWI Ltd
22 Defects:

a Lack of inter run fusion would be considered more serious than answer c.
b Slag inclusions would be considered more serious than answer a.
c Lack of fusion (surface breaking) would be considered more serious than
answer a.
d Both answer a and c would be considered to have the same seriousness as
they are both lack of fusion defects.

23 ISO 17637:

a The minimum light illumination required for visual inspection is 350 Lux.
b The minimum light illumination required for visual inspection is 500 Lux.
c The minimum light illumination required for visual inspection is 600 Lux at
not less than 30o.
d Doesn’t specify any viewing conditions for visual inspection.

24 Flux cored wires may be advantageous over solid wires because:

a Higher deposition.
b Lower hydrogen contents in the deposited welds.
c Easy addition of alloying elements.
d Both a and c.

25 Movement of the arc by magnetic forces in an arc welding process is termed:

a Arc deviation.
b Arc misalignment.
c Arc blow.
d Stray arc.

26 A crack type most associated with the submerged arc welding process is:

a Hydrogen cracking in the HAZ.

b Solidification cracking.
c Lamellar tearing.
d Fatigue cracking.

27 MMA welding process:

a Uses a constant voltage.

b Uses a flat characteristic.
c Uses a drooping characteristic.
d Uses both a and b.

28 Which of the following electrodes and current types may be used for the TIG
welding of nickel and its alloys?

a Cerium electrode, DC –ve.

b Zirconium electrode, AC.
c Thorium electrode, DC +ve.
d All of the above may be used.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-4 Copyright © TWI Ltd
29 Travel speed:

a If too fast may cause low toughness, slag inclusions and cap undercut.
b If too fast may cause high hardness, slag inclusions and a narrow thin weld
bead.
c If too slow may cause high hardness, excessive deposition and cold laps.
d None of the above.

30 MMA welding process:

a Arc blow can be reduced or eliminated by a change from AC to DC current.

b Arc blow can be reduced or eliminated by a change from DC to AC current.
c Arc blow can be reduced or eliminated by a change from DC +ve to DC –ve.
d Arc blow can be reduced or eliminated by a change from DC –ve to DC +ve

31 When considering the tungsten arc welding process what is the purpose of the
down-slope (slope-out) control?

a Ensure good penetration.

b To prevent arc striking on the parent material.
c To help prevent the formation of crater pipe and possible cracking.
d To help prevent tungsten inclusions during welding.

32 Thermal cutting:

a Local hardening can be reduced by increasing the cutting speed.

b Local hardening can be reduced by the use of propane as a fuel gas.
c Local hardening can be reduced by pre heating the material to be cut.
d All of the above.

33 In a MMA welding process, which of the following statements is true?

a An arc gap, which remains almost constant even if the welder varies the
position of the electrode.
b A voltage, which remains almost constant even if the welder, varies the arc
gap.
c A current, which remains almost constant even if the welder, varies the arc
gap.
d Both a and b.

34 When considering the MIG/MAG welding process which of the following metal
transfer modes would be the most suited to the welding of thick plates over 25mm,
flat welding position?

a Dip transfer.
b Pulse transfer.
c Spray transfer.
d Globular transfer.

35 TIG welding process:

a For the welding of aluminium a DC –ve current is preferred.

b For the welding of aluminium a DC +ve current is preferred.
c For the welding of aluminium an AC is preferred.
d All of the above.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-5 Copyright © TWI Ltd
36 Which of the following statements is false?

a In the MMA welding process AC current produces the deepest penetration.

b DC electrode positive is used for the MAG welding of steel plate.
c In the MAG welding process the wire feed speed remains constant during the
welding operation.
d All of the above.

37 When considering hydrogen, which of the following welding processes would

produce the lowest levels in the completed weld? (under controlled conditions)

a MMA.
b SAW.
c TIG.
d FCAW.

38 In steel the element with the greatest effect on hardness is:

a Chromium.
b Manganese.
c Carbon.
d Nickel.

39 For a given voltage and current settings on a MMA welding plant, when the arc
length is shortened, which of the following will be most affected?

a The current will increase.

b The current will decrease.
c The voltage will decrease.
d The voltage will increase.

40 Which of the following best describes a semi-automatic welding process?

a The welder is responsible for maintaining the arc gap and travel speed.
b The welder is responsible for travel speed only arc gap is kept constant by the
welding plant.
c Both travel speed and arc gap is controlled by the welding plant.
d All of the above.

41 When calibrating a mechanised MAG welding plant, which of the following applies?
(WFS = Wire feed speed)

a Check – WFS, current, volts and wire diameter.

b Check – WFS, joint set-up and gas flow rate.
c Check – Gas flow rate, stick out length, WFS and current.
d All of the above.

42 Which of the following fillet welded T Joints would have the highest resistance to
fatigue fractures, assuming material, welding process, filler material to be the
same?

a A convex fillet weld throat thickness 10mm.

b A mitre fillet weld throat thickness 8mm.
c A concave fillet weld throat thickness 8mm.
d Both a and b (throat thicknesses dimension the same).

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-6 Copyright © TWI Ltd
43 MAG welding process:

a 1.2KJ/mm would be a typical heat input value.

b 12KJ/mm would be a typical heat input value.
c 1.2Jouls/mm would be a typical heat input value.
d 6.5KJ/mm would be a typical heat input value.

44 During visual inspection of a fillet weld with even leg lengths of 15mm, the throat
thickness is measured at 8.5mm, what is the fillet welds profile?

a Convex.
b Mitre.
c Concave.
d Both a and b are correct.

45 Which of the following welding parameters are the most difficult to control during
the welding operation using a manual arc welding process?

a Travel speed.
b Deposition rate.
c Current.
d Arc length.

46 Brittle fractures:

a The susceptibility in steels will increase with the formation of a fine grain
structure.
b The susceptibility in steels will increase with a reduction in the in-service
temperature to sub-zero conditions.
c The susceptibility in steels will increase with a slow cooling rate.
d All of the above.

47 Which of the following are considerations for the selection of a preheat

temperature?

a Carbon equivalent, joint design, welding process and plate material quality.
b All Joints over 25mm thick, hydrogen levels, welding process, carbon
equivalent.
c Arc energy, material thickness, hydrogen scale and carbon equivalent.
d All of the above are considerations for the selection of a preheat temperature.

48 Mechanical testing:

a Toughness can be measured with a macro test.

b Toughness can be measured with a nick break test.
c Toughness can be measured with a tensile test.
d Toughness can be measured with a charpy V notch test.

49 Welds made with high heat inputs on C/Mn steels, show a reduction in one of the
following properties?

a Ductility.
b Toughness.
c Elongation.
d Penetration.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-7 Copyright © TWI Ltd
50 Which of the following elements, which may be added to steel, has the greatest
effect on creep strength?

a Tungsten.
b Manganese.
c Carbon.
d Molybdenum.

WIS5-90516b
Appendix 1 – MSR-WI-2a A1-8 Copyright © TWI Ltd