WELDING INSPECTION TECHNOLOGY Sample CWI Fundamentals Examination THIRD EDITION Published By American Welding Society Education Department American Welding SocietyQR CERTIFICATION AWS Certicetions | Accredited Test Facilities BODY OF KNOWLEDGE To help you prepare further .. . This is the breakdown of the Bo category and the approximate percentage of questions drawn fr FUNDAMENTALS. Welding Processes Heat Control and Metallurgy Weld Examination Welding Performance Definitions and Terminology ‘Symbols - Welding & NDT ‘Test Methods - Nondestructive Reports and Records Destructive Tests Conversions and Calculations PRACTICAL APPLICATIONS Procedure and Welder Qualifications Mechanical Test and Properties Welding Inspection and Flaws Nondestructive Tests rom each, lumber of Te ns, 16 12 14 14 23 15 12 10 7 4 12 1 Number of Total Questions dy of Knowledge for the CWICAW!FA F2 F3 Fa FS Fe Welding inspection Tecnmeiegy Suinple CW! Fundamentals Sxamination co ieatly cut w High-carbon steel b, low-carbon stee! ¢. steel d. cast iron e. © and d above Electrical conductivity of a parts the primary requirement for which NDE method? a ET b UT. c PT 4 RT © none of the above ‘The melting point of carbon steel is approximately: a -2250°F b. 23759F c. 2780°F d. 3005°F & 3333°F | Decibel is a term associated with which NDE method? a. UT bo oORT © MT 4 Pr 6. ET Which type of GMAW metal transfer results in the least amount of penetration? a globular b. short circuiting ©. spray d. pulsed spray globular spray ‘Which of the following gases is not commonly used as a shielding gas for GIAW? argon carbon dioxide helium argowhelium none of the above peaogeFe F9 FAO Fil F12 tion "wenn aiogy 2is Examination ro be ace & change the origina! juspection report to indicate the par’s acceptance b. mark directly on the part © fill out a second inspection report 4 e tell the foreman ta have the part moved to its next operation none of the above When a metal is alloyed, how ate the atoms of the alloy incorporated into the original metal lattice structure? by inclusion substitutionally interstitially aorb above borcabove eaogp A wire IQI is used in which NDE method? a UT b ET ec RT 4. MT e PT Which of the following is not used as a semiautomiatic process? a GMAW b. FCAW c OAW a sw ® cand d above none of the above Crater cracks are most often the result oft a. improper technique b. improper filler metal ©. improper base metal 4. all of the above none of the aboveF13 Fig Fis FI6 FI7 Fis cing Ing Sample CW! Fundamentais Ea: The til ofa welding symbol 4. denoting weld! ». denoting welding 2 requirements © denoting welding electrode requirements 4. denoting welding specification requirements e. all of the above During tempering, as the temperature increases, which of the following are correct? hardness increases hardness decreases elongation decreases a and above b andic above peoee In GMAW, the distance from the end of the contact tube to the are is: a arc length b. electrode extension c. stickop 4. aandb above © band c above Of the following, which is not a type of metal transfer in GMAW? a spray b. short circuiting globular 4. pulsed are © open circuiting traviolet light may be used with which NDE method? VT Ul a. b Pr © MT d— aandbabove @ band above The technique which does not aid in reducing residual stress is: a peening b. vibratory stress relief ¢. thermal stress relief 4d. external restraint preheating ection TechnolegyF20 Fat F23 Faq ° Paere es all of the above Part dimensions can be determined using which of the following? a MT b oUT ec ET 4. aand ¢ above e. band ¢ above OF the following tests, which are used forth actual determination ofa material's toughness? a. Charpy test MT chemical analysis all of the above none of the above sans Which of the following elements are used as alloying elements with tungsten to produce GTAW electrodes? a zirconium b. thorium ¢. — columbjum @. aorb above @ bore above For single bevel-groove weld symbols, the line of the AWS weld symbol running perpendicular to the reference line is always drawn on which side? & on the right b. onthe left © on either side, depending on company policy 4. on the side in which the straight side actually appears in the joint €. does not matter The surface between two pieces to be joined that lie in parallel planes is called: weld interface faying surface weld edge groove face none of the above SaneF26 Fo7 F28 F29 F30 2 t09 slow S welding electrode too large d. improper electrode manipulation © use of electrode in a position other than that for which it was designed NDE technicians are usually qualified in accordance with the requirements of: a AWS DII b. API1104 ¢. ASNT SNT-TC-1A d. ASME Section VI e. ASME Section IX ‘Which factor listed below has the least effect on the amount of residual stress and distortion that results from welding? a heat input b. phase changes ©. welding position 4. tensile strength © coefficient of thermal expansion Capillary action plays a role in which NDE method? ET Ur RT PT MT Spogp Ifa welder is continually tuming outrejectable work, the welding inspector should: a. inspect his work mote critically b. ask that the welder be fired ©. require that the welder be retested for qualification 4. instruct the welder in the proper techniques €. ask that the welder use another process Which of the following tests can be used to judge weld soundness? nick break side bend face bend radiography all of the aboveF32 F33 F34 F35, F36 <. Welding at the end of e joint d. welding in comers © all of the above Shielding gases used for GMAW can include: & carbon dioxide b. argon helium oxygen €. all of the above Developing is one of the steps in which NDE method? UT RT PT aand b above band c above Spogp Which discontinuity below will provide the sharpest MT indication? @ surface porosity b. surface crack ©. subsurface porosity 4. subsurface crack €. indications will be identical for all of the above In SMAW, an increase in arc length results in: a. increased current; increased voltage b. decreased current; increased voltage ©. increased current; decreased voltage 4. decreased current; decreased voltage ®. none of the above Weld inspection reports should always: 2 be completed in ink, or typewritten and signed b. be done in pencil so mistakes can be easily comected ©. be maintained only if the weld is rejectable 4. by filled out by a clerk so that everything is readable © include the welder's identificationFa7 F38 F39 F40 Fat Fag hastagy by Examination ‘owing properties amet harduess b toughness ©. tensile strength 4. fatigue strength & ductility In GMANY, the type of metil transfer requiring a special power source is: & spray b. globular ©. pulsed are 4. short circuiting ©. none of the above Which of the following is truly a volumetric test method? a RT & UT ce ET d. MT €. none of the above Use of preheat will result in: a faster cooling rate and wider heat-affected zone 2 faster cooling rate and narrower heat-affected zone a slower cooling rate and wider heat-affected zone a slower cooling rate and narrower heat-aifected zone none of the above Seep Which of the following methods is most likely to use a cathode Tay tube for the presentation of flaws? a RT bo OET e« UT d. aand b above 7 | © bande above For plain carbon steels, how are hardiness and tensile strength related? increase hardness; decrease tensile strength increase hardness; increase tensile strength decrease hardness; increase tensile strength aand c above hardness and strength are not related Snoopfelciing inspucson Tas! Sainple OW Fury Fag Fa4 Fas Fag. Fa7 Fag y amination welding variable controtied by t tickout one of the above ‘The welding variables used to calculate heat input are: voltage and current current and travel speed voltage, current and travel speed travel speed, preheat temperature and voltage voltage, current and preheat temperature Sao gp ‘As temperature increases: . tensile strength increases D. tensile strength decreases ©. ductility increases 4. aand b above €. bande above Which of the following provides the best protection from radiation? . lead shielding steel shielding concrete shielding copper shielding maximize distance from radiation p Pao Welding inspection should be performed: . before welding begins during welding after welding is completed all of the above only when there is a problem Paogp If the weld symbol straddles the reference line, it means: weld both sides weld arrow side first Weld other side first weld has no side significance none of the aboveFas F50 F51 F52 F53 F54 b.-BCAW, GTAW, PAW ©. ESW, LBW, FW a. PW, CAB, RSW e. all of the above An E7016 SMAW electrode exhibits which of the following charac 2 low hydrogen; AC only; iron powder b. low hydrogen; AC and DCEP ©. low hydrogen; AC and DCEP; iron powder d. rutile; DCEP €. rutile; DCEP; iron powder Piezoelectricity is a material property used by which NDE method? a UT b OET «RT 4. aand babove e. band c above A thermal treatment that follows quenching and restores some of the metal’s ductility is referred to as: 2, stress relief b. tempering c. hardening d. normalizing €—postheat Which of these methods is most often used to reduce the high residual stress created by welding? a. prebending b. shor blasting © quenching rapidly after welding 4. postweld heat treating ©. none of the above The physical principle that permits the migration of liquid penetrants into very fine surface discontinuities i 2. magnetic permeability b. optical fluorescence ¢. capillary action 4. emulsification enone of the aboveF56 F57 F5s Fs9 Feo * are brazing braze welding ip brazing flow brazing be © 4. e. ‘Which of the following contzins ferrous base metal specifications? a AWSD11 b. ASME Section HI, Part C e AWSAS1 d. ASME Section IX e. ASME Section I, Part A Which of the following is not considered to be a satisfactory method of magnetization when conducting a magnetic panticle test to a specification? AC coil AC yoke DC coil DC prod residual magnetism Saogee Advantages of MT include: a. the detection of surface flaws b. both AC and DC methods ¢- the detection of surface flaws tightly closed by carbon, slag or contaminants 6. the fact that itis faster than PT ©. all of the above 1h general, an increase in the carbon equivalent of a carbon steel will result in an increase in its: a ductility b hardness strength 4 aandb above € bande above A welding process commonly used to join light gage stainless steel tubing for critical applica- tions is: a SMAW b. =GMAW c. GTAW da OFW © none of the above 10Fe1 F62 Fes F64 F6s F66 91 Teck nology 5 Examination Sample CWE her weld metal ca eerking incomplete penetration porosity bandd above “hich of the following cea result when hydrogen is introduced into the molten weld pool? porosity weld cracking delayed cracking all of the above none of the above Entrapped slag can result when using: Saoep SMAW SAW FCAW ESW all of the above ‘The material property that best describes its ability to withstand a static load is: Pao gp method? a PT b oRT ce MT d, all of the above © none of the above if Saogp hardness toughness tensile strength fatigue strength none of the above no information appears to the left of a groove weld symbol, this means: no weld is required on that side the weld is to be complete joint penetration the weld is to be continuous for the entire length of the joint no weld joint preparation is required none of the above 1"Fes Feo F70 Fri F72 lamination porosity Slight incomplete fusion at a bevel angle of 350 degrees 4a crack with its depth parallel to radiation beamn e aand ¢ above Dwell time is a term associsted with which NDE method? a MT b PT ce RT a ET none of the above The material property expressed in terms of an endurance limi a. fatigue strength b. toughness © tensile strength 4 ductility © — hardness Fracture toughness results will often be expressed in tems of: breaking energy tensile strength percent elongation endurance limit reduction of area SaRoop Shielding of the molten pool in OFW is accomplished by: & a granular flux b. achemical reaction can inert gas d. a vacuum chamber €& — aflux paste ‘The welding inspector is usually responsible for which of the following? checking for proper electrode storage verification of a welder’s qualification witnessing all repairs aand b above band ¢ above See ge 2 lineF74 F75 F76 F78. ©. the recommended type of current the degree of penetration e all of the above ET can be used to detect which of the following? a material’s conductivity a material's hardness a thin material's thickness ‘a material's heat treatment all of the above peoge For an SMAW electrode, the next to the last number in the designation refers to: the tensile strength of the weld deposit the positions in which it can be used the type of coating the recommended type of current none of the above Pepe ge ‘The property of a material that best relates to its resistance to impact loading is: endurance limit fatigue strength fracture toughness tensile strength’ ductility papee Of the following ‘discontinuities, which is least likely to be the result of an improper welding technique? 2. porosity b. Jamination ©. undereut d. crack ©. none of the above Which of the following is considered to be an advantage of VT? discontinuities can be located and noted when they occur it is capable of detecting subsurface discontinuities it can be done very economically aand c above none of the above saooe 130 the public? in the perf: of his duties for inspections that he has personally perforined reporting all nonconformities to the news media none of the above paps FO Which of the following cunnot be done in the overhead position? a SAW b ESW ec. GTAW d. all of the above €. aandb above F81 No information appearing to the right of 2 groove weld symbol means: the weld is to be complete joint penetration no weld is required on that side the weld is to be continuous for the entire joint length ‘no weld joint preparation is required none of the above saogp F82 The welding process that typically uses a tubular electrode is: a SMAW b. GMAW c. FCAW a SAW « ESW 83° The property relating to a metal’s resistance to indentation is: a. tensile strength b. ductility ©. hardness 4. toughness ©. fatigue strength F84 ET is the abbreviation for: & eddy current testing “ b. — environmental testing ©. emissive testing 4 aandb above e band above 4Fas Fee F87 Fes. Fsg Foo icing Inspection Sarr 7 c AWS 43.0 ¢. aand b above & band c above The flux covering on an SMAW electrode provides which of the following? a g28 shielding for the molten poo! 6. are stabilization ©. alloying 4. deoxidation all of the above a b a TePart the deficiency to the proper supervisory personnel 4. require that the parts be disassembled and properly assembled © none of the above The orientation ofthe probing energy source with respect to tha ofa flaw is considered to be a significant variable for which NDE method? a RT b oUT c. ET ad MT. €. all of the above Information that appears tothe left of the weld symbol refers to: 2 the weld length b. the weld size © the electrode size 4. the number of passes required ©. none of the above ‘Which process uses a granular flux? a SAW b. «GTAW c ESW G. aand b above ® aand c above 15F9y Fo2 F93 Fo4 F95 Fo6. stituents listed below, the fy austenite Pearlite In radiography, the image on the film of a completely through-cracked weld will; 2. appear as a well-defined, low density lightly shaded, sharp line b. appear as a well-defined, high density, darkly shaded, sharp line © appear as a row of iow density light spots or dots 4. appear as a row of high density dark spots or dots © none of the above A material's ductility is commonly expressed in terms of: a. percent elongation b. percent reduction of area ©. tensile strength 4d. aandb above ©. bandc above Who is responsible for the qualification of welding procedures? & independent test lab b. contractor ©. welding inspector @. > architect engineer ‘What MT technique could be used for the discovery of longitudirial flaws? a. head shot b. circular magnetization ©. longitudinal magnetization d. aandb above € band above ‘Which code gives prequalified status to certain weld joint configurations? a APL1104 b AWS DLAI ¢. ASME Section IX d ANSIB31.1 ©. none of the above 16Fos. Fog F100 Fi01 F102 appears to the "ess to be used) ype of electrode to be used ©. length of weld required size of weld req © required joint configu: 8 When a clerical mistake is made while completing an in Sspection report, the inspector should: a ‘erase the error and fill in the correct information b. cross out the error and supply the proper information © Tine out the error with a single line, supply the proper information, and initial and date the occurrence in ink 4. attach a note to the report explaining the reason for the change e none of the above The rapid quenching of a high carbon steel from the austenitizing range will result in the formation of: a pearlite b. martensite ©. cementite ad ferrite © austenite When an austenitized carbon steel is cooled to room temperature, an increase in the cooling rate will result in: 4 an increase in hardness and a decrease in ductility b. an increase in tensile strength and a decrease in hardness ¢. a decrease in tensile strength and an increase in hardness d. an increase in ductility and a decrease in hardness a decrease in hardness and an increase in ductility The surface finish of the specimen affects the test results for which of the following? a tensile strength b. fatigue strength ©. impact strength 4. all of the above e aand c above The heat treatment in which a carbon steel's temperature is raised to the austenitizing range, held for a prescribed time and then allowed to cool to room temperature while remaining in the furnace is referred to as: a stress relief b. annealing ©. normalizing 4. tempering e. — austenitizing 7F104 F105 F106 F107 F108 When a weld has been ¢ plete of carbon s g Citection f ductiliny? aand b above band c above ted by a qualified NDE technician, the welding inspector should: review the test results end maintain the test record teinspect to verify the defect accept the weld if its visual appearance is in compliance with the applicable code or specification tequire another inspection by a third party accept the weld since itis in a low stress region Equal thicknesses of steel, cast iron, aluminum, lead, and copper are radiographed using the satne exposure conditions. Which material will result in the darkest radiograph? eeoge lead steel aluminum copper cast iron ‘The welding process that uses a nonconsumable electrode is: a b. © a. e GMAW SAW GTAW FCAW SMAW ‘The heat treatment in which the metal’s temperature is raised to the austenitizing range, held for prescribed time and then allowed to cool to room temperature in stil] air is referred to as: a. b e ch e. austenitizing normalizing annealing quenching tempering Ina guided bend test, the bend radius is: a b ce a. e always 5 inches as specified in the appropriate code or specification 0.5 inch 0.65 inch none of the above 18F110 Fi11 F112 F113 Fig Th A a be c a e It excess moisture. To determine the extent of the surface and subsurface Porosity that resulted, which NDE method would be most effective? a b. cs 4. « Saoge ‘The heat treatment for carbon steels in which the metal’s temperature is raised to just below the lower transformation temperature and held for a preseribed time before allowing it to cocl at a controlled rate is referred to as: a papoose FOAW SMAW GMAW none of the above he AWS Centfied Weiding inspecior must be capable of. welding performing PT performing chemical analysis supervising welding none of the above break in the arrow line has what significance? Welding must first be done on the arrow side Welding must first be done on the other side Welding must be done alternately on both the arrow and the other sides The broken arrow line segment points to that member which receives some preparation none of the above is discovered that a GMAW mild steel weld was produced with a shielding gas containing MT RT VT tempering austenitizing stress relieving normalizing preheating | 19Pris F116 FII7 Fig F119 F120 lie position on @ meial’s str plas Yield point 2. modulus of elasiicity © endurance limit transformation temperature © Young’s Modulus Low-hydrogen electrodes can be properly store 2 ina natural gas oven b. inan electric oven © ina vented electric oven d e in a vented gas oven none of the above All welding symbol information referring to the arrow side of the Joint is found: in the tail above the reference line below the reference line where the inspector decides none of the above Spo ge ‘The marking of a rejectable weld should: be clear and understandable to all involved be made with a steel impression stamp note the proper repair procedure always be in red always include the welder’s identification Cannot be used effectively to inspect: austenitic stainless steel welds on carbon steel austenitic stainless steel welds on stainless steel] carbon steel welds on carbon stee] @ and b above band c above PeeorR Spee Of the welding processes listed below, the one most ‘commonly having the highest deposition rate is: a ESW bo FCAW c SAW d SMAW e GMAWFi21 F122 F123 F124 F125 F126 The vse of pre tem carbon steet wil} of hydrogen cracking ¢. result in the formation of martensite a and b above band ¢ above The tensile test can be used to provide values for which of the following? a yield point >. ultimate tensile strength c. modulus of elasticity 4. elastic limit €. all of the above Which of the following is not an acceptable method for control of raw materials? & color coding b. alpha-numeric coding c. first in, first out d. location segregation €. barcoding ‘The welding inspector's duties should typically include: the acceptance/rejection of welds the verification of a weld filler metal type the development of weld repair procedures aand b above band c above gaoge All welding symbols require which of the following basic elements in their construction? reference line, arrow and tail reference line and arrow reference line, arrow, weld symbol reference line, arow, weld symbol, dimensions and supplementary data reference line only paoge ‘The size of the weld represented in Figure I: a. isnot important smaw b. cannot be determined directly from the symbol ©. can be determined from the symbol d. all of the above e none of the above Figure 1 aF128 F129 F130 F131 F132 asingtion fon provide pure T raguires liet weld the use of shi all of the above metal are welding pRoer A SMAW weld was produced in which the welder failed to properly clean between passes in a multipass weld, Which nondestructive test would best reveal the flaws that may be present in the completed weld? a RT b& VT «MT da PT e ET ‘SMAW can be used in which type of application? semiautomatic a RESTRICTION RING b. machine ©, manual d. alll of the above TEST WELD €. none of the above sas ‘What position is depicted in Figure 2? a 6G be 5G c ° OF d 6GR 7 none of the above Figure 2 Using the appropriate conversion factor provided in the chart on page 40, determine the approx- imate diameter in inches for an electrode that measures 1.2 mm. a 0.047 in, db 47in c. 0.0047 in, dd 47in, e 47.2in, Underbead cracking is primarily caused by: a source of hydrogen restraint excessive preheat all of the above none of the above Sao eEFI33 F134 F135 F136 F137 F138 fection? jamentals & mperatere below 80)°F 6 it can be dove in an inert ‘gas atmosphere dit relies on capillary action e ic, and d above Which weiding process uses a constant current power source? GMAW >’ SMAW c GTAW 4. aandb above band c above ‘The first operation required by the symbol in Figure 3 is: UT ultrasonic inspection of the base metal VT visual inspection of joint preparation welding a V-groove from the other-side of the joint welding a backing weld from the arrow-side of the joint back gouging and back welding from the arow-side of the joint Figure 3 Spogp For Figure 3, ultrasonic inspection is to be performed: @ on the back weld only on the entire length of the other side weld on 10% of the weld length from the arrow side bandd above Saeg Which of the following discontinuities are associated with shrinkage stresses in the through thickness direction of thick plate? 7 crater cracks lamellar tears ._ toe cracks Toot cracks none of the above Pao Which of the welding techniques below describes a welding process in which the filler metal feeding is machine operated while the joint travel speed and guidance are the responsibility of the welder? semiautomatic manual machine automatic none of the above gaosre 4 depicis: followed bya V le followed by Figure 4 id made one-half the w a V-groove weld arrow-side with the root fi around the diameter of a pipe hed to a convex contour F140 Which of the following symbols correctly describes the joint configuration shown in Figure 5? = ane . c Figure § a ‘1/4 (7/16) 174 (7716) © none of the above FIAT The width of the cut produced during a cutting process i referred to as: root opening kerf bevel bevel angle chamfer pRooe F142 For the 2G position in pipe welding: 2 the axis of the pipe is vertical and the plane of the weld is horizontal the axis of the pipe is horizontal and the plane of the weld is vertical the pipe is not fixed Paes one of the above F149 During operation, the heat for electrosiag welding is provided by: . the are the electrical resistance heating of the molten slag the consumable guide tube 2 and b above band above Spo oe 24 the axis of the pipe and the plane ofthe weld are at 45 degree angles with the vetical planeF144 F145, F146 F147 F148 F149 ension factor j he char on page 40, determine the approx ewe ¢off) for a flow ree of 22 titers per minute b. 4e.6 cm 10.38 ofa 4 03.8cfh e. 4.66 eth Its suspected that a GMAW weld was produced in an area where there was an excessive draft, Which nondestructive test would best reveal the intemal discontinuities which may have resulted? a PT b. MT «RT @ UT e. none of the above The size of the arrow side weld in Figure 6 is: a V4 inch b. 5/16inch feet c Jinch a inches ©. none of the above Figure 6 The length of the other side weld in Figure 6 is: a." Vinch b 6 inches ©. 2inches 4 4inches ©. continuous down the length of the joint ‘The pitch of the other side weld in Figure 6 is: 1/4 inch 4 inches 5/16 inch linch 6 inches paogp The process to be used in welding according to Figure 6 above in question 148 is: a. the inspector's choice b. the fabricator's choice ©. not stated dd. bandc above e aand b above 25F151 F152 F153 F154 F156 sonination te a ET BOM? c PT ad UT e ET ‘The phrase. “that surface of a member included in the groove” best describes: a. root opening b. groove angle ¢. weld interface 4. groove face € none of the above Crater cracks can be the result of: a. poor welding technique restraint shrinkage Bectroge, Slap Molten Fix b, ce .— underfill of crater €. all of the above Figure 7 depicts which welding process? a SAW sola SE Welded 4 GMAW © FCAW ‘The boundaries indicated by “ a. fusion line b. depth of fusion c. weld interface d. fusion face €. none of the above ‘The dimension “D” in Figure 8 is referred to as: a. fusion face b. fusion zone c. depth of fusion d. weld interface ml fusion line 26 Contact Tube Nozzle Flaxia from Hopper Fu Blanket Motes Base Metal Weld Metal Path Direction of Trav ——— Figure 7jon Technolo: aC a p> @. none of the above F157 Using the appropriate conversion factor provided in the chart on page 40, determine the approx- imate degrees Celsius for a preheat temperature of 25°F, a 225°C b 107°C ce. 437°C a 107°C e 107°C F158 Which of the following welds is not considered applicable for a butt joint? a. V-groove b plug ©. edge-flange d. U-groove e. Iegroove F159 The dimension “A” in Figure 9 refers to: a. root penetration b. weld penetration cc. depth of fusion d. joint penetration ©. none of the above F160 The dimension “C” in Figure 9 identifies: a. joint penetration and weld size b. weld size and root penetration c. depth of fusion d. partial joint penetration incomplete joint penetration F161. The dimension “B” in Figure 9 is referred to as: joint penetration Toot penetration root reinforcement aand b above band c above eaereF163 F164 F165 F166 moamesstots Ex ination the following is nota iype of wel When using SMAW, wet electrodes will most likely cause: a. underevt b. overtep ©. underfill 4. porosity ©. all of the above Which ofthe following is considered to be an acceptable way to provide backing for a V-groove weld in a carbon steel butt joint? & copper backing bar b. ceramic backing ¢. flux backing d. backing weld ¢. all of the above A welder deposits an average of 12 pounds of weld metal Per hour. Using the appropriate con- version factor provided in the chart on page 40, determine the approximate kilograms of weld ‘metal that will be deposited in 6 hours of continuous welding, a Skg b 33kg cb kg a 26 kg e 37kg A single-wire, submerged arc welding machine is Operating at 32 volts, 600 amps and is travel- ing at 8 inches per minute, Using the formula provided. what is the tert input for this situation? Voltx Amperage x60 _ Sin, ‘Travel Speed (in,/min) 7 2,400 Win, 1,152,000 J/in, 1.44 x 105 Jin, 110,000 Jin, 14,400 Win, saorp 28F187 F168 F169 F170 Fi71 F172 ing Iepestion Te empie #1 Fundementals & nation hibits an ssively convex pro- h fi sprite acto 2 it, since its a aonselevant indicotion b. reject the weld c correct the excess convexity and retest d e secept the weld none of the above ‘The pipe welding test position ia which the pipe is horizontal and rotated so that welding takes place at or near the top is designated as: 2G bo OF 3 a 3G e 1G The design strength of a fillet weld is always based on the throat dimension because: a, thas a columnar microstructure, which is more prone to cracking b, itis the shortest failure path through the weld ¢. itis the location of most defects d. the design calculations cannot be checked ¢. itis theory of failure that cannot be supported by actual laboratory testing Are strikes are discontinuities most commonly associated with: a ESW b SAW ©. SMAW a. aand babove @& bande above Double-groove joints always require: backgouging special welding processes high deposition rate processes weld to be deposited from both sides of the joint a spacer to hold critical root openings Saogeainination 2 process is depicied in b. MAW c SMAW 4, e, SAW ESW sours we F174 Light-colored areas within the weld he zone in a radiograph could represent: 2. porosity tungsten inclusions melt-through aand b above band c above METAL Wo S80, onoPLEtS Peneraanion oem BASE METAL PIRECTION OF WELDING ————a b. < Figure 10 e F175 A single-groove joint always requires: a. special welding processes b. back gouging ©. abacking bar 4. no root opening ©. none of the above FI76 The substance used in UT to aid in the transmission of sound from the search unit to the work: piece and back is called: a solvent b. attenuation © couplant @ cable e transducer FI77 Using the appropriate conversion factor from the chart on page 40, determine-the approximate Kilogram weight of a 30 pound roll of welding wire. a 136 kg b 66 kg e136 kg d 66.15 kg e 136k F178 The junction of the weld face with the exterior surface of the base metal is referred to as the: a” face b. root ce leg 4 toe e. edgeF178 F180 F181 F182 F183 vinations ave best revealed vs «ET Porosity in GMAW can be caused by: a drafts 6. contamination ©. too little shielding gas flow 4. too much shielding gas flow €. all of the above ‘The overhead fillet position is designated as: a SF bd 4E ce 3F 4 2F e IF The radiograph in Figure 11 shows: Inspection T oimciegy damentak, Exomination, a cracks b. incomplete fusion ©. incomplete joint penetration d. slag inclusions ©. none of the above Figure 11 ‘The welding process depicted in ‘Thamovor wanna Figure 12 is: GMAW cet ise SAW SMAW ror GTAW Booy sc PAW ‘COLLET BODY paoge MOLTEN anc WELD METAL Figure 12 31 ELECTRODE: SHIELOING GAs NONCONSUMABLE TUNGSTEN ELECTRODE. SouoirieD, WELD METALF185 F186 F187 F188 Figg re 13 sho) nclusions or soot defects tangsten inehusions porosity longitudinal crack e. undercut aan How many micrometers ere in one meter’? @ 3,000,000 b 1,000 ce. 100 4. 1,000,000,000 none of the above In a groove-weld cross section, the ‘line’ separating weld metal from base metal is called: a. the fusion face b. the depth of fusion ©. the depth of penetration d. the weld interface ©. none of the above In the radiograph in Figure 14, the arrows point to: a. transverse cracks b. acrater crack ¢. a longitudinal crack d. an underbead crack €. none of the above Figure 14 Incomplete fusion can be caused by: a porosity b. weld joint contamination ©. undercut 4. poor fitup e banddabove In pipe groove welding, the 45 degree fixed position is designated as: a 1G b 26 c 2F d 5G e 66F130 Figt F192 F193 F194 Figs peed i 83 ipa bd. 283 ipm © 2834 ipm 4 5.076 ipm € 50.75 ipm The detect noted in the radiograph in Figure 15 a. incomplete penetration b acrack ©. incomplete fusion 4. porosity ©. none of the above The “A” dimension in Figure 16 is referred to as: weld throat b. weld size cc. weld leg 4. aand b above bande above in Figure 16 points to: the root penetration the weld penetration the weld root the joint root none of the above Figure 16 a. b. ©, 4 e. ‘The dimension “C” in Figure 16 shows: @ the theoretical throat b. the actual throat ¢. the effective throat 4. aand b above & bande above The dimension “D” in Figure 16 is called: a, the theoretical throat b. the effective throat c. the actual throat d. aand b above e. bande aboveF1g6 F197 F198 Fisg F200 F201 One common cause of centerline weld cracks is Sap ee the theoretical throut Jeg and weld size concavity the use of preheat # highly restrained weld joint using the wrong polarity stress relief heat treatment the presence of incomplete sidewall fusion Figure 16 Using the appropriate conversion factor from the chart on Page 40, determine the approximate Pounds per square in. (psi) for a yield strength of 198 MPa’ a b. c a. e. discontinuity? a. b, c 4. e Using the conversion factors provided in the chart on page 40, determine the approximate MPa for a tensile strength of 65,000 psi. a. 2.871 x 103 psi 2.871 x 104 psi 4,136 psi 41.36 psi 2,871 psi intermittent less distinct PT cannot detect a subsurface flaw none of the above 448,000 4.48 x 108 448 9,425,000 | 9.425 x 106pitten F203 F204 F205 F206 F207 sharper Jess distinct MT cannot detect a subsurface flaw } inch below the surface none of the above Which of the following conditions can cause slag inclusions in a weld? poor welder technique careful interpass cleaning insufficient preheat aand b above band ¢ above geaos To be most effective, visual inspection must be conducted: before welding during welding after welding all of the above band ¢ above paneer ‘The dimension “B” in Figure 17 is: athe weld leg b. the weld size c. . point of tangency d. aandc above e aand b above The dimension “A” in Figure 17 is the: a convexity b. concavity ¢. face reinforcement 4 aande above © bande above ‘The dimension “C” in Figure 17 is: the actual throat the effective throat the theoretical throat aand b above band c above epaege Figure 17F208 The dimension “Din F a. the actual throa: fective thn ne theoretical 1 d. aand b above © band above gare 17 is; “ F208 Where should the preheat temperature be measured? in the weld groove 12 inches from the weld groove where the arc will be initiated 2-3 inches from the weid groove Figure 17, reheat temperature need not be measured ¢ Pao op F210 A discontinuity is: a. always rejectable b. sometimes rejectable c. always a defect d. sometimes a defect e. band d above F211 What weld discontinuity is shown in the radiograph in Figure 18? a crack b. incomplete joint penetration © bum through 4 hollow bead | ©. ° tungsten inclusions Figure 18 F212 An oxygen regulator is set for 40 psi. Using the appropriate conversion factor from the chait on | + page 40, determine the pressure in kPa, 2,758 27,580 2.758 27.58 : 2758 | pooge F213 Which of the following discontinuities can be caused by poor welding technique? a. incomplete fusion b. porosity c. undercut: ‘overlap ©. all of the above |F215 F216 F217 F218 F2ig é © require requalitic ¢. instruct the welder in proper techniques ©. ask that the welder use another process Which of the following discontinuities is seldom discovered during VT? crack b. incomplete penetration on plate ¢. surface porosity ¢. tungsten inclusion ©. none of the above throat crack crater crack underbead crack porosity centerline crack A megapascal is equal to: a 1,000 Pa b. 1,000,000 Pa c 1,000 kPa qd. aandb above e band c above Which of the conditions below can cause porosity in a weld? a. welder technique ‘b. damp electrodes ©. oily base metal 4. rainy weather €. all of the above Which of the following discontinuities is not associated with GTAW? lack of fusion slag inclusions tungsten inclusions porosity undercut SP aegeWeidiry insp, Sample Cw) F220 Using the apptopriate con 27 pm to mins, on page 40, vel speed of F221 Pot ann ttsion factor from the chart on page 40, cto are iath in MP2 of e tensile specimen having a ere section of 0.300 at a tensile load of 24,600 pounds, ulate the ultimate tensile square inch which broke Load (pounds) i F = Tensile Strength (ps ‘Area of Specimen (square inch ~ TMsile Strength (psi) 565 Pa 565 MPa 5.65 Pa 565 kPa 5,650 kPa a b. °, 4. e. F222 Which of the following discontinuities ae not associated with GMAW? 2 slag inclusions b. porosity ©. tungsten inclusions ..- 4. aandb above e, aandc above F223 The CAWE a B _ inspects weldments only under the dieting ot CWI or SCWI & cannot inspect critical weldments | 4. performs inspections the same asa CWI ; © all of the above | F224 NDE technicians are certified in accordance with: a AWSD1I | He b. APT 1104 | ¢. ASNT SNT-TC-1A d. ASME Section VI €. ASME Section IXANSWER KEY a a b bd © e © © a a e b b e e d e e a a b. b b © c d © e é e e db b a a c b c e b © c e e B47 Fas F49 F50 FSI F52 FS3 F54. FSS FS6 FS7 F58 F59 F60 F61 Fo2 F63 F64 F65 eoasn THO TOO AR ONT EATON TO CReME FATHOM OA OOOO ono aEH F110 Fill FIZ FH3 Fld FS FIG FUT FLU8 FLI9 Fi20 F121 F122 F123. F124 F125 F126 F127 F128 F129 F130 F131 F132 F133 F134 F135 F136 Fi37 F138 a Ro roe eee mor oT race nwa oon oH cao rronRogaAN eon Gora PI3s F140 FI41 Fl42 F143 Flag 14s F146 F147 F148 F149 FiSO FIS1 FIS2 F153 FIS4 FISS F156 FIS7 F158 F159 F160 FI61 F162 F163 F164 F165 F166 F167 Fi68 Fi69 F170 FI71 F172 F173 FI74 FIIS F176 Fl77 F178 F179 F180 Fi81 F182 F183 F184 as peciicn Technology ination Creer ree nooo soars eam acanccoobacarce manWweising inepecti Tect:notogy Fureamen 7 bxamination WIT—Useful Formulae Area of Square or Rectang'e ‘Area=length xwidth or Area = width x thickness Area or Circle Area=mxradiys? or Arse = mx or Area = 0.7854 x diemeter? diameter? 4 Percent Elongation ton = Final Gage Length ~ Original Gage % Elongation alee ont Sa Sogo Lareth ooh x10 Percent Reduction of Area «= Original Area — Final Area 1s Reduction oe = eg x 100 Tensile Strength General uts = Pmax where: P max = load to break specimen * ixrea Area = specimen’s original cross-sectional area Pipe UTS for full section pipe = TOT Yield Strength yg = Load at specified ofset Original cross-sectional area Welding Heat Input. * Une VxAx60 where: J = Joules (energy) “~ Travel Speed (ipm) V = welding voltage A= welding amperage ‘ipm = inches per minute Carbon Equivalent CEs C+ + Bt 44Welding sispeciiea Techno! Sample CW! Funearenta ®acsinedion Welding Usaga Conversion Chart— Property* To Conver: Frem: To: area cimensions . vin? seereeeeee MM, mm? wee Lae in? current éansity ANN Aime? sm ain? deposition rate... ‘bir = kglht kghhr toh. flow rate = fh. rin . min. heatinput 22... dn vn cei mm... fi. linear measure . Wire feed speed... infin $ Customary and $1 Multiply By: +1 M52 x 102 «1550x109 + 1550x109 + 6.452 x 108 ATI9x 104 2119 = 39.37 + 254x102 254 = 3.937 x 102 = 3.048 x 102 = 3.281 x 103 - 6.895, 6.895 x 10-9 oe O45 + 1.450 x 102 = 1450 69x 107 33/18 CC x 1,8) +32 6.895 x 10 1,450 x 102 2383x1071 2.362 = 7.501 x 10% 0.423 «2.362Of the following, which is considered an important duty of the welding inspector? QL-1 a. Itis a welding inspector's responsibility to judge the quality of the product in relation to some form of written specification. b. A welding inspector functions as a judicial representative of an organization. c. A welding inspector must be able to interpret the specification limitations and intent. d. all of the above e, none of the above QI-2 Of the following, which is not considered an important attribute of a welding inspector? a. welding experience . inspection experience c. professional attitude d. engineering experience e. ability to be tained Qi-3 ‘What document describes the important bie aie of the AWS Certified Welding Inspector program? a. AWSDI.1 b. AWS AS.1 c. AWSQC1 d. AWS D14.1 e. none of the above Ql-4 Asa welding inspector, must you know how to weld? a. yes, according to AWS D1.1 b. yes, according to AWS QC i ©. yes, if inspecting highway bridges d. no, according to AWS D1.1 €. not mandatory, according to AWS QC 1Qus b c QL-6 Qu7 paoge When may you, as 4 welding inspector, speak out on maiters cf public policy? when paid by an interested party or parties anytime, if no money interest is involved after disclosing all possible financial connections of the statement, criticism, or argument presented when the statement is based upon adequate facts, upon a background of technical competence pertinent to the subject,and upon honest conviction of the accuracy and propriety of the statement Welding inspectors should never make public statements Which of the following are important ethical requirements for the welding inspector? integrity professional ability good physical condition ‘volunteering public statements regarding an inspection for personal exposure. all of the above Of those attributes considered to be important to the welding inspector, which is probably most influential in his gaining the cooperation and respect of others with which he works? ability to be trained professional attitude ability to complete and maintain inspection records good physical condition ability to interpret drawings and specifications ‘The welding inspector is likely to work in which of the following industries? shipbuilding automotive bridge construction pressure vessel construction all of the abovecording te the squ rorents of the AWS CWI pregram, what is d cfa welding iaspector? vision necessary 20/20 rarusal 20/20 corrected vision 20/40 natural vision 20/40 corrected vision 20/40 natural or corrected vision Which of the following could be considered essential knowledge for a welding inspector? nondestructive testing welding symbols welding processes destructive testing all of the above When a weld requires repair due to some deficiency, to whom should your inspection report be directed? to the welder whose mark is on the weld to another welder, better trained to the project engineer to the welding engineer to the welding foreman or supervisor What professional attributes are most helpful in performing inspection duties? being informed, impartial and consistent in your decisions being close friends with welders and superiors being a former welder being a non-union employee being a nondestructive examination technician as well as CWIQU-33 b. c. d. e. QLt4 a b. e. d e. QU-1s SROs With wh ork on respons welding engine welding foreman welders inspection supervisor all of the above 2 during the performance of his What document defines the proper terminology for use by the CWI? AWS QC 1 AWS A3.0 AWS DL AWS AS.1 none of the above With regard to drawings and specifications, the CWI must: be familiar with engineering drawings and able to understand specifications. memorize the content, memorize those portions of these documents applicable to a particular job. all of the above none of the abovegaogp Of those listed below, which is an acceptable way to correct an error on an inspection report? Draw a line through the incorrect portion of the report. Erase the incorrect word or words. ‘Throw away the report. Line out the error, make the correction, and initial and date the correction. none of the above What records should you keep as a CWI? copies of reports of all inspections you perform copies of reports relevant to your areas of responsibility (material test reports, welder qualification paperwork, procedure qualification paperwork, etc.) even though you didn’t prepare them copies of sales literature describing welding equipment boih a and b all of the above ‘When a particular type of weld is consistently marginal, with rejects occurring, what action would be appropriate for you as the inspector? Tell the welder what you want. Bring the problem to the attention of engineering personnel in order for corrective action to be teken, if possible. Simply continue to accept or reject the welds according to specified criteria [no more action is appropriate for inspectors). all of the above none of the aboveQ2-7 aes ich must be immediately accepted or iejected ‘cular joint. Who should rule on the A specification for a weld joint ks detailed information about that p meaning end intent of the specification? the designer the welding engineer the project engineer or quality assurance personnel {if their approval is required by contract] you, as the CWI none of the above How can you identify an individual low hydrogen electrode which a welder is already consuming to make a weld? Read the classification numbers painted on the covering near the stub end of the electrode. Ask the welder what it is. Ask the welding foreman. Look at the completed weld and identify the type of electrode by the visual appearance of the weld deposit. Look on the drawing or specification to determine what type of electrode is required for that weld. How should low hydrogen electrodes be stored before use? in their original unopened containers in ovens held at a temperature which assures the maintenance of their low moisture content in tool room cribs, properly labeled, ready for quick distribution either a orb all of the aboye- ‘What joint fit should you insist on? within tolerances specified on drawings or specifications Groove welds should have minimal root openings to reduce distortion. root openings greater than 1/8” to assure complete penetration Fillet welds should have root openings so that the resulting weld’s effective throat will be greater, none of the aboveERT yo OS ETT TT EERE ee Eee ENR, $$ Which welders aze ailewed to work on ode" jols? a. only those with certification papers from former jobs b. only those tested by the “abricator for this particular job ¢. 4. e. only those qualified in accordance with job specifications only those you have requalified for this job all of the above Q2-9 How should low hydrogen electrodes out of their original containers be stored? a, in their original resealed containers i b. in heated storage ovens : ©. in open tool crib shelves : d, in individual welders’ electrode pouches # e. none of the above Q2-10 How can a CWI verify that the specified material is used on the job? ‘ a. For code jobs, each piece of material must be correctly: marked with its identity. b. Perform a quick carbon analysis with a field test kit. ¢. Material must be scrapped if no identification is evident, 4. Once the material leaves the storage area, the CWI no longer has to verify it e. none of the above Q2-11 Ifa mill product has imperfections such as splits, tears or surface irregularities, what action should you as the inspector take? a, Reject any imperfect materials. b. . Judge whether or not the imperfections meet acceptance criteria according to applicable job specifications c. Ignore the ixregularities if not in the immediate vicinity of the weld joint. d. Wait until the welder finishes the weld to see if any cracking occurs before making any judgment. €. none of the abovePEREMA TE LTR TN ERE TET EE EON T EE UMEY PEE 249 ditions bala s Q2-12| Which o 2, One of the welders seers te hav grade of s1 ag usec b. Every Monday, five of the welders make poor welds, but the rest of the week all goes well. One of the welders produces undercut with welding in the vertical position, | Cracking is repetitive when welding a certain steel alloy. @. none of the above ap Q2-13 Which of the following is a welding inspector's responsibility prior to welding? Check joint fit. Check preheat temperature. Check interpass temperature. aand b above band c above saogep G14 A 1/4” fillet weld is specified on the drawing. When the CWI inspects the weld, it is measured to be 3/8.” What should be done? Reject the weld for being oversize. Accept the weld if no weld size tolerances are specified. Ask for an engineering review of the design, band c above none of the above Pane ge Q2-15 Fillet welds should be measured using what tolerance? a. + 1/16" b, +132” c. -1/16” d. -1/32" €. no tolerance SAEEPLTSOE LTTQ3- a. b. c. 4 e. Q3-2 a b. ¢ d. e 3-3 a b, c d. e Q3-4 ES 5 Job quality requirements can be found in all but which of the following? codes standards specifications text books a&b only Of the following documents, which may be considered a “standard”? codes specifications recommended practices aand b above all of the above ‘The type of document which has legal status is: - code standard specification both a and b above . all of the above ‘That type of document which describes the requirements for a particular object or component is referred to as: code standard specification aandb above band caboveIh fact, the specific types of this classificetion, standards - specifications drawings none of the above The code which covers the welding of steel structures is: ASME Section IX ANSI B31.1 API 1104 AWS D1.1 none of the above The code which covers the design and fabrication of unfired pressure vessels is: ASME Section IX ASME Section VIII ASME Section IT API 1104 AWS Dil The specification covering the requirements for weldin, ig electrodes are designated as: AWS DLX AWS DI4.X AWS ASX ASTM A53 ASTM A36 The standard describing the requirements for Welding of crosscountry AWS DL ASME Section VII "ASME Section IX API 1104 none of the aboveQt4 Pao gp Sap ge Which of the following is not considered a typé of joint? butt T fillet comer edge ‘The type of joint formed when the two pieces to be joined lie in parallel planes and their edges overlap is called: corner T edge lap butt That portion of the joint where the two pieces to be joined come closest together is referred to as the: bevel joint root groove angle Toot face both b &d Ina single-V-groove weld, the sloped surfaces against which the weld metal is applied are called: toot face . joint root groove face groove angle bevel angleQ4-6 Pao sp Q4-7 Saogp Q4-8 gaege Q4-9 eee gp ripasrs: pot weld seam weld slot weld none of the above ‘The type of weld having a generally triangular cross section and which is applied to either a T-, corner or lap joint is called a flange weld flare weld fillet weld slot weld spot weld The type of weld used to build up thinned surfaces, provide a layer of corrosion protection, provide a layer of abrasion-resistant material, etc. is referred to as a: edge weld 7 flare weld flange weld slot weld surfacing weld The type of weld applied to the opposite side of a joint before a single-V-groove weld is completed on the near side of a joint is called a: melt-through weld backing weld back weld root weld none of the above In a completed groove weld, the surface of the weld on the side from which the welding was done is called the: crown weld reinforcement weld face root none of the aboveQs-10 eRoge Q411 spose Q4-12 eaoe Q4-13 saege 4-14 es paoge on between the weld fece and the base metel is vconipleted weld, be j > the: root weld edge weld reinforcement leg weld toe The height of the weld above the base metal in a groove weld is called the: crown buildup face weld reinforcement none of the above Ina fillet weld, the leg and size are the same for what type of configuration? equal leg concave convex unequal leg oversize | When looking at the cross section of a completed groove weld, the difference between the fusion face and the weld interface is called the: depth of fusion depth of penetration il root penetration joint penetration effective throat For a concave fillet weld, which throat dimensions are the same? theoretical and effective actual and effective theoretical and actual all of the above none of the aboveQ4-15 epee Q4-16 Seo se Q4-17 Seo ep Q4-18 fapoe Q4-19 eaoge beeeenaeroraergeacs “7 “groove weld, the ditension meesured from the th Ina partial penetration sing joint roct ‘0 the weld rect joint pereiration effective throat root penetration depth of fusion weld interface The size of a spot weld is determined by its: depth of fusion spot diameter depth of penetration thickness none of the above In the performance of a vertical position weld, the type of weld progression having a side-to-side motion is called: stringer bead technique stagger bead technique weave bead technique unacceptable none of the above Which of the following is only found in a single-welded groove? weld face weld root weld toc root reinforcement face reinforcement The technique used to control distortion of a long joint where individual passes are applied in a direction opposite the general progression of welding in the joint is called: backstepping boxing staggering cascading blockingQ4-20 Spore A technique onger tien the pre dlock sequcase box sequence cascade sequence backstep sequence stagger sequence Questions Q4-21 through Q4-28 refer to Figure 1 below: Q4-21, a. pao gs Q4-22 eRoge Q4-23 PROS ‘The weld face shown in Figure 1 is labeled: 1 2 3 6 7 The weld root shown in Figure 1 is labeled: yavne ‘The type of weld shown in Figure 1 is a: double-bevel-groove | single-bevel-groove i double: V-groove single-V-groove none of the above04-25 Sao se Q4-26 spege Q4-27 epee Q4-28 Spogp be weld cerfircemer nin Figure 1 is Jab i 1 2 3 6 7 The weld toe shown in Figure 1 is labeled: Nabe Number 6 shown in Figure 1 is the: weld root fusion face groove face Weld interface depth of fusion Number 5 (between arrows) shown in Figure | is the: weld root fusion face groove face weld interface depth of fusion Number 4 shown in Figure 1 is the: weld size joint penetration actual throat theoretical throat aand b abovepov Foun Q4-29 The weld face shown in Figure 2 is labeled: a 7 b 8 ce 6 dol e. 10 Q4-30 The weld root shown in Figure 2 is labeled: a 6 4 5 9 3 epos Q4-31. The welds shown in Figure 2 are: a. concave fillets b. conical fillets c. convex fillets d, T-fillets e, fillet of fish Q4-32. The actual throat shown in Figure 2 is labeled: aol b 2 a 3 d. 10 ae 9 ions Q4-29 through Q4-4) :e%: to Figure 2 below:a SBoge 4-34 Saegp 04-35 fae op Q4-36 Paoge Q4-37 Paegp The weld i 8 10 7 both aandd 2 shown in Figre 2 is Number 6 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fasion Number 9 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fusion Number 5 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fusion Number 4 shown in Figure 2 is the: weld root fusion face groove face weld interface depth of fusionQuestions Q4-41 through Q4-45 refer to Figure 3 below: effective throat actual throat theoretical throat aandb above Number 3 shown in Figure 2 is the: weld size effective throat actual throat theoretical throat aand b above Number 10 shown in Figure 2 is the: weld size and leg size weld size Jeg theoretical throat actual throat Vy jE Q4-41 The groove angle shown in Figure 3 is labeled: sao ee THe URED| 4°23 Q4-42, Tho bevel angle show in Vigure 3 is wpe Q4-43 Number 3 shown in Figure 3 is the: 2. groove angle b. devel angle | c. groove face d. fusion face e. cand d above Q4-44 Numbei 6 shown in Figure 3 is the: a, groove'face b. fusion face c. bevel face d. root face ©. bevel Q4-45 Number 5 shown in Figure 3 is the: . fusion face b. groove face c.- root opening d. root face e. weld root4-46 pao op Q4-47 eaogp 04-48 eae ge 4-49 Panos e 4 below ‘The weld faces shown in Figure 4 are labeled: 8&2 9&7 T&S 1&6 3&9 The weld root shown in Figure 4 is labeled: 1 2 3 7 aandc above The weld shown in Figure 4 includes a: backing weld back weld double-V-groove double-bevel-groove none of the above The weld size shown in Figure 4 is labeled: 9 8 7 2 none of the aboveQ450 be o d. e. Q4-51 Number 6 shown in Figure 4 is the: a. weld root fusion face groove face weld interface depth of fusion sao Q4-52 Number 5 shown in Figure 4 is the: weld root | fusion face i groove face weld interface depth of fusion : Sao Q4-53 Number 4 (between arrows) shown in Figure 4 is the: a. weld root fusion face groove face weld interface - depth of fusion Pees Q4-54 Number 2 shown in Figure 4 is the: root surface fusion face weld face i weld interface depth of fusion eaogeQ4-55. The bevel angle shown in Figure 5 is labeled: Q4-57 The groove face shown in Figure 5 is labeled: -5: a b. ¢, 4. e. 4-58 a. b © a. e ks 2 E| 4 cand d above The joint root shown in Figure Sis labeled: Rone none of the above 1 2 3 4 cand d above The root face shown in Figure 5 is labeled: 1 2 3 4 none of the abovesh Q4-69 refer to Figure 6 beloy Q4-59 The weld face shown in Figure 6 is labeled: aol b 4 oe a3 ete Q4-60. The weld root shown ‘in Figure 6 is labeled: 6 4 5 9 10 Seog e Q4-61 The welds shown in Figure 6 are: concave fillets conical fillets convex fillets T-fillets fillets of fish Pao se Q4-62 The actual throat shown in Figure 6 is labeled: a 9 10 3 2 5 eaos63 ‘The weld toe shown in Figure 6 is labeled: Tit 1 both a and d above Q4-64 Number 6 shown in Figure 6 is the: a, weld root b. fusion face c. groove face 4. weld interface . depth of fusion Sas ra eae RA a Na dai 24-65 Number 8 shown in Figure 6 is the: a. weld root b. fusion face c., groove face a. weld interface e. depth of fusion Q4-66 Number 5 shown in Figure 6 is the: a. weld root fusion face toe weld interface depth of fusion eo Beg Q4-67 Number 2 shown in Figure 6 is the: weld size leg size leg and weld size theoretical throat actual throat Pee eeCREEP ED ISS try ee ee EEE Eee QE-68 Rember 3 showa in Fige¢ € is the: weld size leg leg and weld size theoretical throat actual throat Number 9 shown in Figure 6 is the: effective throat weld size leg d..- theoretical throat e actual throatQ5-3 Q5-4 Sao eaege The primary element of any welding symbol is referred to as the: tail arrow reference line arrow side weld symbol Information appearing above the reference line refers to the: near side arrow side far side other side none of the above The graphical representation of the type of weld is called the: tail welding symbol weld symbol arrow none of the above Which of the symbols below represents the weld shown? S 2 S @. none of the abovepaogee Q5-7 & pao gp oO m pao op When a weld that the welder put the weld on either side. that there is no side significance. that the designer doesn't 't know where the weld should go. that the welder should weld in whatever position the weld is in. none of the above The symbol below depicts what type of weld? flare-V-groove flare-bevel-groove edge-flange corner-flange none of the above In the symbol below, the 1/8 dimension refers to what? 418 groove angle Toot face depth of preparation weld size root opening In the symbol below, the 3/4 dimension refers to what? 3/4 (7/8) weld size effective throat depth of preparation root opening none of the shove ibol is centered on the reference lin, this indicates:& Q5-9 Ifapplied to 2 } inch thick weid, the symbol below represents what type of weld? 5/16 (1/2) 5/16 (4/2) full penetration double-bevel-groove weld full penetration double-V-groove weld partial penetration double-bevel-groove weld partial penetration double-V-groove weld none of the above saoge Q5-10 Dimensions appearing to the left of the weld symbol generally refer to the: a, weld length b. weld size/depth of preparation c. root opening d. radius e. none of the above Q5-11 A wiangular-shaped weld symbol represents what type of weld? a. bevel-groove b. flare-groove c. flange-groove d. V-groove c. none of the above Q5-12 The symbol below represents what type of weld? 2-4 24 staggered intermittent fillet weld chain intermittent fillet weld segmented fillet weld intermittent fillet weld none of the above a b c d,soos lly refer to the: ight of the weld symbol Dimensions appearing to the weld size root opening depth of preparation weld length/pitch none of the above ‘A weld symbolized by a rectangular box that contains a dimension represents a: plug weld slot weld plug weld in beveled hole partially filled plug weld ! plug weld in hole having dimension shown ‘The required spot weld size can be shown as: a dimension to the right of the symbol a dimension of the required nugget diameter a value for the required shear strength aandb above band c above ‘A number appearing to the right of the spot weld symbol refers to: spot weld size spot weld length number of spots required pitch distance between adjacent spots none of the above In the symbol below, the “A” dimension represents: A BC weld size flange radius flange length depth of penetration none of the aboveQ5-18 1a the syrabol below, the symbol shown on the oth NSH | back weld 2 side represenis. backing weld melt-thra weld aand b above band c above paoge Q5-19 The symbol below shows the use of what type of weld? single-bevel-groove weld single-V-groove weld backing weld back weld band c above eaoge Q5-20. The symbol below shows what type of groove configuration? square groove skewed groove sloped groove scarf none of the above Pao oeQE21 The part of the welding symbol which can bé used to convey any additional information which canact be shown otherwise is referred to as: a. the weld symbol b. the arrow c. the reference line d. the tail e. none of the above Q5-22 The symbol below shows what type of weld? GTAW a gas metal are spot weld b. resistance spot weld ¢, gas tungsten arc seam weld d. resistance seam weld €. none of the above Q5-23 What nondestructive examination method is to be applied to the ‘arrow side? PT MT a. magnetic particle testing eddy current testing radiographic testing penetrant testing none of the above = pao Q5-24 A number in parentheses just outside a test symbol represents: a. the length of weld to be tested the extent of testing the number of tests to perform the type of test to perform oie of the above onosyctive examinatica symbol refers to the: Q5-25 A number to the right of a nonde: a. ber of tests to perform b. the length of weld to be tested c. the applicable quality standard Gd. the test procedure to use e. none of the above Q5-26 Which of the symbols represent the weld shown below? NI | x a. b. o. d. 2. none of the above Q5-27 Which of the symbols represent the weld shown below? d. a. b. c e. none of the aboveQ5-28 Which of the symbols represent the weld shown helow? | Lg @ di b. G d. @. none of the above , Q5-29_ Which of the symbols represent the weld shown below? RIK OE a. b. °. d. @. none of the above Q5-30 Which of the symbols represent the weld shown below? OE A a b, ©, d. . none of the aboveik Lt a b. c d. e. none of the above Q5-32 Which of the symbols represent the weld shown below? | a a e. none of the above Q5-33 Which symbol represents the welds shown? a 4 4 5 ANN a b. c. a. &, none of the above Pepeeeeeuet - |Q5-34 Which of the welds is rey esented by the symbol below? a b. © a. @. none of the above Q5-36 Which of the welds is represented by the symbol below? ' a b. c d @. none of the aboveof the welds i d by the syinbol below? 95-37 W e. none of the above Q5-38 Which of the welds is represented by the symbol below? axa a. b. c d. e insufficient reference or detailing Q5-39 Which of the welds is represented by the symbol below? by @ c| |e GEE €, none of the aboveBREUER PEER E ee ee of the welds pit — epiesented by the symbol below? Q @ SiS Sa a. b. ce. e. none of the above Q5-41 Which of the welds is represented by the symbol below? @ 66 a b. c e. none of the above Questions Q5-42 through Q5-46 refers to Figure 1 below: ws 3-10 1/4} 7 3-10 FIGURE 1 Q5-42. What is the weld length? a 1/4" db. 3/3” eueee d. 10” @. none of the aboveQ5-46 paose ace? What is the pitch dis 10” none of the above What is the size of the arrow side weld? 1a” 3/8” 3" 10” none of the above What is the size of the other side weld? 1/4” 3/8” 3" 10” none of the above What does the symbol represent? fillet welds on both sides intermittent fillet welds chain intermittent fillet welds staggered intermittent fillet welds none of the aboveDR en Ba EEE EEE: Questions Q5-47 through Q5-51 refer to Figure 2 below: et iva 6 45° FIGURE 2 QS5-47 What is the pitch distance? none of the above ; Q5-48 What is the angle of the countersink? ar b 12° c. 45° a 6° e. « none of the above Q5-49 What is the depth of filling? sete b 12" c. 45" ae e. none of the above Q5-50 What is the weld size? a 1” b 1/2" ce. 45" da 6" €. none of the above Q5-51 What weld is represented by the symbol? a. arrow side slot weld b. other side slot weld c. arrow side plug weld 4. other side plug weld @. aoreabovean [ARERR Suara name moras ne ae meinen Questions Q5-52 through QS 1/4 (38) |Z \ 12 @H9N What is the arrow side depth of preparation? wa” 3/8” 12" 9/16" 15/16" What is the other side depth of preparation? var 38" 12" sie" 15/16” What is the other side weld size? 1/4" 3/8” v2" one” 15/16” What is the arrow side weld size? 1/4” 3/8” 1/2” oe” 15/16" What is the total weld size? ua" 3/8” V2” 9/16" 15/16" 56 refer to Figure 3 below:e1g As a metal is heated: energy is added to the structure. the atoms move farther apart. the atoms vibrate more vigorously. the metal expands. all of the above The state of matter which exhibits the least amount of energy is: solid liquid gas quasi-liquid none of the above A problem occurring in weldments caused by the nonuniform heating produced by the welding operation is: porosity incomplete fusion distortion slag inclusions none of the above All but which of the following will result in the elimination or reduction of residual stresses? vibratory stress relief extemal restraint thermal stress relief pening postweld heat treatmentSteel exists in which of the following crystal arrangements? HCP FCC BCC aand b above band c above Rapid cooling of a steel from the austenitic range results in a hard, brittle structure known as: pearlite carbide cementite bainite martensite Very slow cooling of steel may result in the production of a soft, ductile micro structure which has a lamellar appearance when viewed under high magnification. This structure is referred to as: martensite pearlite bainite ferrite cementite When rapid cooling produces a martensitic structure, what non-austenitizing heat treatment may be applied to improve the ductility of the steel? quenching tempering annealing normalizing none of the above The use of preheat will tend to: result in a wider heat affected zone produce a lower heat affected zone hardness slow down the cooling rate reduce the tendency of producing martensite in the heat affected zone all of the aboveQ6-10 Sao ge Q6-11 pao gD Q6-12 oP Sao Q6-13 pRogp Q6-14 Spe gp Which of the following changes will decreased carbon equivales increased carbon equivaler:t increased base metal thickness a and c above band c above vit the addition or increase in the What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in the furnace? normalizing quenching annealing tempering stress relief What heat treatment is characterized by holding the part at the austenitizing temperature for some time and then slow cooling in still air? normalizing quenching annealing tempering stress relief Increasing the heat input: decreases the cooling rate and increases the likelihood of cracking problems. decreases the cooling rate and decreases the likelihood of cracking problems. increases the cooling rate and increases the likelihood of cracking problems. increases the cooling rate and decreases the likelihood of cracking problems. none of the above Increasing preheat: decreases the cooling rate and increases the likelihood of cracking problems decreases the cooling rate and decreases the likelihood of cracking problems. increases the cooling rate and increases the likelihood of cracking problems. increases the cooling rate and decreases the likelihood of cracking problems. none of the above Sea os a |a b. G, d. & Q6-18 a. b. c d. e. Q6-19 Increasing the carbon ocn‘e at decrease ued of cracking problems, 60.1 9: cracking problem: has nothing to do with the likelihood of cracking problems. all of the above none of the above Which of the following generally follows quenching? annealing normalizing quenching tempering stress relief Which of the following can be accomplished using either thermal or mechanical techniques? annealing normalizing quenching tempering stress relief, Which of the following results in the softest structure for steel? annealing : normalizing quenching tempering stress relief For a steel Having the following composition: 0.11 carbon, 0.65 manganese, 0.13 chromium, 0.19 nickel, 0.005 copper, and 0.07 molybdenum, what is its carbon equivalent using the following formula? CE=%C + (2M) + (%Ni) + (ZCI) + (%Cu) + (%IVio) 6 15 5 14 4 eae sp 0.15 0.23 0.28 0.31 0.42on: G.16 carbon, 0.85 manganese, 0.25 6.41 riolybdenum, what is ste carbon 6 4 0.23 0.31 0.34 0.41 0.46 pao re Questions Q6-21 through Q6-24 refer to the Heat Input formula below: Heat Input (J/in) = Amperage x Voltage x 60 Travel Speed (in/min.) Q6-21 The FCAW process is being utilized to weld a ] inch thick structural steel member to a building column. The welding is being done with a 3/32 inch diameter self- shielded electrode with a 150° minimum preheat and interpass temperature, The welding parameters are adjusted to 30 volts, 250 amperes and 12 in/min, What is - the heat input? 375 Vin 37,500 Jin 375 kI/m aand b above band c above pages Q6-22, GMAW (short circuiting) welds are produced at 18 volts, 100 amperes and 22 infmin, What is the heat input? a, 238 J/in bd. 7333 Jin ce, 4909 Vin dg. 30J/in e, none of the above $$ |R sae gp PROD 1 ir 650 Vin 650,000 J/in 165,000 J/in 16,500 Jin none of the above The GTAW process is being used for welding 1/16” thick titanium using DCEN at 110 amperes, 15 volts and 6 in/min. What is the heat input? 21000 J/in 21 ki/in 16,500 J/in aand b above band c aboveQ7-3 eRe op ‘Which property cannot be determined from a tensile test? ultimate tensile strength percent elongation percent reduction of area impact strength yield strength ‘The property which describes the ability of a metal to deform or resist some applied load is: strength toughness hardness ductility none of the above The point at which a metal's behavior changes from elastic to plastic (onset of permanent deformation) is referred to as: yield strength ultimate tensile strength modulus of elasticity Young’s modulus none of the above Which of the following is an expression for a metal’s ductility? percent elongation ercent reduction of area proportional limit aand b above band c above sainQ7-s What is the perceat elcae tion of a specimen y inches and final gage ler g'h was 2.5 inches? 25% 50% 40% none of the above hose criginal gage tengih wes 2 ‘The property of metals which describes their resistance to indentation is called: strength toughness hardness ductility none of the above The type of testing which is used routinely for the qualification of welding procedures and welders is: tensile strength hardness soundness impact strength all of the above Of the following, which properties can be determined as a result of tensile testing? ultimate tensile strength ductility percent elongation yield strength all of the above ‘The family of hardness tests which uses both a minor and major load is called: . Brinell Vickers Rockwell Knoop none of the aboveQ7-12 a b. c d. e. Q7-13 a. saos Q7-14 PS Bo ge Which of she o.loy tig tusts are referred to as imierchardness tests? Knoop aand b above bandc above What type of test uses a weighted pendulum which strikes a notched test specimen? Brinell test fatigue test tensile test crack opening displacement (COD) Charpy impact test Of the following, which is one of the most measurable features of a metal? fatigue hardness soundness tension none of the above Which of the following is not considered a soundness test? tensile face bend fillet break root bend nick-break ‘The type of testing used to evaluate the type of microstructuré present in a metal is called: tensile hardness toughness metallographic none of the abovenetely how many kg? €, none of the above | Q7-16. Which two metal properties are directly related for many steels? a. impact strength and fatigue strength b. tensile strength and ductility c. tensile strength and hardness d, toughness and fatigue strength €, none of the above Q7-17 What is the wire feed speed which is measured to be 175 in./min? 125 m/s 74 mm/s 7.4 mm/s | aand b above bandc above PRO sp Q7-18 The property of metals which describes their ability to carry some type of load is: a. strength toughness hardness ductility none of the above eaBos Q7-19 For less ductile metals, which method is used to determine the yield strength? drop of beam offset technique stress-strain curve abrupt yielding none of the above ope eerictl to al orb energy is called. strength ductility hardness toughness none of the above A weld joint is measured and found to be 345 mm long. How long is that joint in terms of inches? 135.8 in 13.58in 8760 in 876 in none of the above Which of the following tests are used to verify the soundness of a weld? nick break fillet break bend test radiographic test all of the above With the SAW process we achieve a deposition rate of 19.7 kg/h. How many Ib/h is this? 434 lb/h 43.4 Ib/h 87.5 lbh 8.9 lb/h, none of the above Ultimate tensile strength can be determined using which of the following tests? tensile bend Charpy nick break nil-ductility drop-weightQ7-25 a. b ° 4. e Q7-26 Spee Q7-27 easee Q7-28 Sno Q7.29 Sao gp Calculation of percent elongation is deiermined after measuring the change in: percent reduction of area depth of indentation diameter of indentation cross sectional area length between gage marks With the GMAW process we use a wire feed speed of 170 mm/s. How many in/min is this? 40.16 in/min 53.7 in/min 401.6 in/min 537 in/min none of the above With the GTAW process, flow rates are measured at 22 Limin, How many ft/h is this? 10.4 fen 1.39 fti/n 46.6 ft3/h 83.2 f5/h none of the above Calculation of tensile strength is accomplished by dividing the tensile load by: cross sectional area percent elongation percent reduction of area gage length none of the above The metal property describing its freedom from imperfections is: tensile strength soundness impact strength toughness ductilityQ7-30. Ifa metal exhibits « grsut deal of elongation prior to falling when a tensile load ig applied is said to have high a. tensile strength b. hardness c. impact strength d. toughness e. ductility Q7-31_ A specimen approximately 2 long with a V-notch machined in the center of one Of its sides is used for which of the following tests? a. tensile b. nil-ductility drop-weight c. Charpy d. bend e. tuck break Q7-32 A heat input of 1,500,000 J/m is how many J/in? a. 381 JS/in b. 3,810 J/in c. 38,100 Jin d. 381,000 J/in €. none of the above Q7-33 Which of the following properties can be determined from a tensile test? ultimate tensile strength, yield Strength, ductility yield strength, ductility, toughness ductility only toughness only all of the above eae oe Q7-34 The force required to bend a steel bar is measured to be 890 N. That is how many Ibi? 200.3 Ibf 2003 Ibf -20 Ibf 550 Ibf none of the above SaoopQ7-35 A coating peasy have a ma 68g 682 0.008 g 08g none of the ‘as removed from a SMAW electrode. After weighing, it was found to | of 2.4 02, That is how many grams? | above8.3 Koeaooe PRooD Who is normally responsible for the qualification of welding procedures ai} welders? welder architect welder’s employer independent test lab Code body Which of the following destructive testing methods may be used for procedure qualification testing? tensile nick-break charpy bend all-of the above What is the pipe welding position where the pipe remains fixed with its axis horizontal, so the welder must weld around the joint? 1G 2G 5G at 6G : 6GR What is the pipe welding position where the axis of the pipe lies fixed at a 45 degree angle? 1G 2G 5G 6G none of the aboveg Q8-7 ean ge Q8-8 ppogp Q8-9 cao What is the ne weld T-, K-, 1G 2G 5G 6G 6GR With relation to procedure and welder qualification, what is the most important part for the welding inspector? watching the welding qualification test identifying samples cutting test specimens testing specimens monitoring production welding For most codes, if a welder continues to use a particular procedure, how long does his qualification remain in effect? indefinitely 6 months lyear 3 years until he produces a rejectable weld ‘What document describes the requirements of welder qualification in accordance with ASME? ASME Section Il ASME Section II, Part A ASME Section IX ASME Section XI ASME Section V Qualification to weld cross country pipelines is normally done in accordance with ASME Section Iil AWS D1.1 AWS D143 API 1104 API 650 |paoee Of the following, which is not a necessary requirement for a welding process? source of energy electricity means of shielding molten metal base material none of the above Which of the following are functions of the flux coating of a SMAW electrode? insulating alloying deoxidation shielding all of the above In the AWS system of SMAW electrode designations, the next to the last number refers to: usability electrode cpating position strength none of the above Which of the following is an incorrect statement about a SMAW electrode designated as an E7024? Itis a low hydrogen type. The weld deposit has a minimum: tensile strength of 70,000 psi It is suitable for use in the flat and horizontal fillet positions only. all of the above none of the abovegBO se Which of the following is not an essential part of a typical SMAW system? constant current power supply wire feeder covered electrode electrode lead work lead Shielding of the molten metal in GMAW is accomplished through the use of: granular flux slag fuel gas and oxygen aand b above inert and reactive gases Which of the following is not considered a type of metal transfer for GMAW? short circuiting spray globular droplet pulsed arc Which of the following types of metal transfer in GMAW is considered to be the lowest energy, and therefore prone to incomplete fusion? short circuiting spray globular droplet pulsed arcWhich of the following is not considered an arc welding process? sMAW GMAW FCAW ESW none of the above In the electrode designation system for FCAW, the second number refers to: strength position chemical composition usability none of the above Which of the following is not always an essential element of a FCAW system? constant voltage power supply tubular elebtrode wire feeder shielding ges work (ground) leadWhat aspect of the GTAW and PAW processes is different from the other arc welding processes? nonconsumable electrode power supply shielding all of the above none of the above Shielding for the GTAW and PAW processes is accomplished through the use of: granular flux slag inert gas reactive gas none of the ajove A green stripe on a tungsten electrode designates: pure tungsten’ 1% thoriated tungsten 2% thoriated tungsten zirconated tungsten none of the above When welding aluminum with the GTAW process, what type of welding current is most commonly used? DCEP DCEN AC aand b above band c above SAW and ESW are similar in that: both are arc welding processes both use shielding gases both use a granular flux aand b above aand ¢ aboveQ9-18 Sao Q9-19 The diagram below depicts what welding process? SMAW ESW FCAW SAW PAW Solidification cracking due to improper width-to-depth ratio of the weld nugget may be a problem with which welding’ process? : oFW Sw SAW all of the above none of the above A welding | process done essentially in the flat position with welding progressing from the bottom to top of the weld joint positioned vertically identifies: GMAW SAW ESW aand b above band c above Which of the following are not common to both GTAW and PAW? nonconsumable tungsten electrode copper constricting nozzle shielding gas nozzle extemally-applied filler metal none of the aboveQ9-22, eaogp Q9-23 pang Q9-24 peaoges Q9-25 epegp Q9-26 pap gp What technigue is employed with PAW to produce full penetration welds? stringer beads weave beads keyhole backstep none of the above What welding process produces welds in the flat position, in a single pass, with the progression vertically upward along the joint? SAW ESW FCAW aand b above band c above Which of the following is not an advantage of the ESW process? high deposition rate ease of setup capable of joining thick sections no tendency for angular distortion none of the above. Which welding process is considered to be a chemical welding process? SMAW ESW SAW oAW none of the above Which arc’ welding process provides an efficient means of joining attachments to some planar surface? OAW SW GMAW GTAW SMAW9-32 Q9-27 peoge Q9-28 ep poge Q9-29 sao se 2 S & s sae ep Q9-31 sees Brazing differs from welding ia that: no filler metal is used. an oxyfuel flame is used. the base metal is not melted. all of the above none of the above For satisfactory results, a braze joint should have: a large surface area. a small gap between pieces to be joined. a precise bevel, aand b above bandc above Which of the following is not an advantage of brazing? ease of joining thick sections ability to join dissimilar metals ability to join thin sections. aand b above band c above Of the following metals, which'cannot be effectively cut using OFC? high carbon steel low carbon steel medium carbon steel stainless steel none of the above Which of the following gases can be used to perform OFC? MAPP propane acetylene natural all of the aboveQ0-32 PRogp Q9-33 a b. c. d e. Q9-34 Which of the following cuiting processes can be used to cut any metal? OFC CAC-A PAC aandb above band c above The width of a cut is technically referred to as the: gap dross kerf drag none of the above Which process is illustrated below? Q9-35 GMAW PAW GTAW BMAW CAW ESW designates which process? electric stag are welding electroslag are welding electric slag welding electroslag welding electric stud welding9-34 Q9-36 Which process is illustrated below? GMAW PAW GTAW TIG CAW spe ge Q9-37 Which process is illustrated below? mama | pee wLLLLLA GMAW PAW GTAW TIG CAW seepa. GMAW b. SAW c. GTAW d. SW e. SMAW Q9-39 SMAW designates which process? a. stick metal are welding b. shielded metal arc welding c. submerged are welding d. seam metal ate welding e. short cireuiting metal arc welding Q9-40 SW designates which process? stud welding stud arc welding submerged welding stick welding submerged are welding eBogR Q9-41 SAW designates which process? stud welding stud are welding submerged welding i stick welding submerged arg welding Pao9-36 Q9-42 FCAW designates which process? flux cored arc welding flux centered are welding furnace controlled arc welding friction arc welding flow arc welding saege Q9-43 GMAW designates which process? gas machipe arc welding gas method are welding gas material arc welding gas metal arc welding general material arc welding paegP Q9-44 GTAW designates which process? gas tungsten arc welding general tungsten arc welding globular transfer arc welding gas torch are welding none of the above eaoge 2 S & a PAW designates which process? plasma arc welding pressure arc welding plate are welding percussion are welding none of the above saoge Q9-46 Which of the following could result in the creation of porosity in the GTAW of 6061-16 aluminum structurel members for an aircraft application? insufficient cleaning of the weld joint contaminated filler metal leak in the shielding gas hose presence of drafts during the welding operation all of the above Pao se9-47 paooe Q9-48 pee ge Q9-49 seogP 2 eaogP ‘An BR70S-6 electrode can be used with which of the processes? GTAW GMAW PAW all of the above none of the above A granular flux is @ characteristic of which of the following? ESW SAW SMAW both a and b both b and ¢ ‘Which of the classifications listed below produces the strongest weld metal? ER70S-6 E70T-5 E7018 FTA2-EM12K_ no difference Which process is classified as a chemical welding method? GTAW GMAW ESW PAW OAW Which cutting methods use electricity? PAC CAC-A OAC and b above sdcabove2-33 Q9-52 panos Q9-53 Paoge Q9-54 pans Q9-55 pao Q9-56 eaoge A tubular electrode is a significant characteristic of which process? SAW ESW FCAW SMAW GMAW Which are welding process is used very effectively for the welding of various types of attachments to surfaces of plates and structural members? SMAW GMAW FCAW sw ESW Molding shoes is a term associated with which process? SAW cTAW ESW FCAW GMAW Short circuiting metal transfer is a mode of operation for: GTAW FCAW SMAW none of the above all of the above The need for electrode holding ovens for some types of its filler metal is a Gisadvantage of which process below? SMAW FCAW SAW all of the above aandbQ9-87 eae Q9-58 sae Q9-59 pape sp Q9-60 Sao rep Q9-61 Seoge Which process uses a carbon electrode? SMAW GMAW GTAW CAC-A PAC EWTh-1 is an electrode designation for which of those processes listed below? GTAW PAW GMAW aand b above, band c above Of the following which brazing process is preferred when the parts to be brazed can be assembled with the filler metal preplaced near or in the joint? torch induction furnace diffusion none of the above F7P6-EM12 isa filler metal designation for: SMAW GMAW FCAW. SAW PAW The ability to perform keyhole welding is a primary advantage of: GTAW - PAW SMAW FCAW SAWQ9-62 pees Q9-63, pao es Q9-64 pape Q9-65 gp poge Q9-66 spose Which gases can be used for OFW? MAPP. acetylene natural gas propane all of the above® ‘Which gases below can be used for TB? acetylene oxygen natural gas propane ‘ all of the above A ferrule is an item used for shielding in which process below? ESW PAW PAC SW FB When GTAW is used, what type of current results in the greatest amount penetration? dcen deep ac hwac no difference A constricting nozzle is one of the components for which welding process? PAW GTAW SAW GMAW sw fFQ9-67 gRog Q9-68 pape Q9-69 epoge Q9-70 eaoge Q9-71 pages What gases ¢an be used for GMAW? carbon dioxide argon ‘75% argon-25 % carbon dioxide 98% argon-2% oxygen all of the above The process which can be used either with or without an external shielding gas is: GMAW SMAW FCAW GTAW PAW. Which of the welding processes below is generally considered to provide the highest deposition rate? SAW ESW FCAW SMAW GMAW When welding carbon steel with the OAW process, the torch should be adjusted to provide: an oxidizing flame a carburizing flame a neutral flarne aheating flame none of the above Of the following which of the processes make use of water-injected torches to minimize the effect of irregular kerf? PAC CAC-A cTAW aand b above band c aboveQ9-72 The use of a constricting orifice, is the distinguishing feature of which of i following? GTAW GMAW FCAW PAW none of the above eapee Q9-73 Which of the following processes utilize a flux to provide necessary shielding? SMAW SAW GMAW aand b above all of the above PRoseQ10-1 b. ce. d. e. Q10-2 a. b. c. d, e. Q10-3 eaos Q10-4 aoge A discontinuity is: always a defect. always a reject. always acceptable. rejectable if it exceeds code limits. none of the above Of the following, which is commonly caused by the presence of hydrogen in a crack susceptable microstructure subjected to applied stress? lamellar tearing. delamination. porosity. delayed cracking. none of the above Porosity, o¢curing in the form of large cylindrical pores is called: clustered porosity linear scattered porosity uniformly scattered porosity elongated porosity none of the above Which of the following discontinuities is least likely to be seen visually? toe crack undercut lamellar tear overlapQi0-s sang Q10-6 eaege Q10-7 eaoeP Q10-8 sao FP 1 from which of the following welding practices? Underbead cracks can re: use of wet electfodes welding on contaminzted steels welding over paint all of the above none of the above ‘The weld discontinuity which results from improper termination of the welding arc is referred to as: undercut overlap crater crack incomplete fusion all of the above All but which of the following processes may result in the presence of slag inclusions in the completed weld? SMAW PAW FCAW SAW none of the above ‘That discontinuity which results from the: entrapment of gaé within the weld cross section is referred to as: crack slag inclusion incomplete fusion porosity none of the aboveQ10-8 What befe mete! dsscntiaulyy, located at the weld toe, is caused by the weldes tiaveling too rapicly? 3 underfill undercut incomplete fusion overlap ; none of the above PRO Q10-10 What weld discontinuity results when the welder travels too slowly causing excess weld metal to pour out of the joint and lay on the base metal surface without fusing? undercut underfill overlap incomplete fusion none of the above Sao op Q10-11 What weld metal discontinuity results when the welder fails to completely fill the weld groove? a. underfill b. undercut ©. overlap d. incomplete fusion €. none of the above Q10-12 Excessive weld metal buildup on a groove weld is referred to as: @ excess convexity b. excess weld reinforcement cc. overfill d. all of the above €, none of the aboveQ40-13 The weld distontincity which results from the initiation of the welding are outside the weld joint is referred to as: incomplete fusion undercut overlap scratch start are strike Sao gp QU0-14 Of the following, which weld discontinuity shows up as a light region on a radiograph? a. porosity b. incomplete joint penetration ec, aandbabove d. tungsten inclusion €. none of the above QU0-15 What base metal discontinuity results from improper steelmaking practice and is associated with the rolled surface? Jemination delamination seam crack none of the above es aegp193 Questions Q10-16 through Q10-20 refer to the figure on the Facing pag Q10-16 What discon: is shown by #12b? a, longitudinal crack b, transverse crack c. face crack d. toe crack € root crack QU0-17 What discontinuity is shown by #11? a, lamination b. base metal crack c, lamellar tear dé. seam e lap Q10-18 What discontinuity is shown by #12g7 a. toe crack b. incomplete fusion ¢. root crack 4. e Jamellar tear underbead crack Q1L0-19 What discontinuity is shown by #5? a. undercut b. underfill ©. overlap 4. incomplete fasion e, toe crack Q10-20 What discontinuity is shown by #10? a, lamination b. seam c. delamination 4. base metal crack e. incomplete fusionQU1-4 a. b, c. 4. e. Qui-2 a. b. c. a e. Qu3 b. c d ° QU.-4 sae op Which of the following nondestructive examination methods do not usually requi electricity? eddy current visible dye penetrant visual aand b above band c above Which of the following nondestructive examination methods is limited to U detection of surface discontinuities? visual 4 penetrant magnetic particle all of the above none of the above To be most effective, visual inspection should be performed: before welding. during welding, after welding. all of the above none of the above The time during which the penetrant remains on the surface of the part (0 allow to be drawn into any discontinuities is called: waiting time. penetrating time. soak time. dwell time. none of the aboveQU-S Which type of magnetizing current provides the best combination of penetrationab'lity end pariicle mobility? a AC bv. DC c. half-wave rectified DC a. e. band c above all of the above QUI-6 What NDE method will most likely reveal subsurface porosity? a. PT b. MT ce, RT d. UT allof the above * ° QUL-7 Which of the following statements is correct for a radiographic test? a. A reduction in thickness will produce a light image on the film. b. -A low-density discontinuity will produce a light image on the film. ¢. A high-density discontinuity will produce a light image on the film. d. -aand b above e. band c above QUI-8 Which of the following discontinuities is almost never detected using RT? a. crack b, incomplete fusion c. undercut d, lamination €. none of the above QUI-9 What device is used during radiography to indicate the acquired sensitivity of a radiograph? rate meter dosimeter lead screen penetrameter none of the above RoopQUL-10 Which po: QU1-11 The process whereby the ultrasonic indications are related to physical distances j Pae gp Saoge as @ probir festructive ex 1 method utilizes sound energ mediura? VT RT UT PT ET i a test standard is referred to as: setup | calibration | standardization | synchronization | none of the above Q11-12 A test probe containing an alternating current coil is used for which NDE method? see ge RT UT | ET. MT c&dabave Q11-13 Changes in electrical conductivity can be measured using which NDE method? PRO ep ET RT none of the above Q11-14 Which of the following NDE methods are suitable for detecting surface cracks? a Saos RT VT ET PT all of the aboveQU1-15 Whi y f seveal interna laminations in a rolled plate? a RT b UT ec. ET d. MT & none of the above QU1-16 PT is limited to the detection of those discontinuities which are? a. near the test object surface b. open to the test object surface c. clean and open to the test object surface d. all of the above 9 none of the above QUIL-17 Visible dye Penetrant indications: must be observed under a black light don’t have to be observed under a black light, must be observed under ultraviolet light must be observed under white light none of tlie above but are more sensitive if they are Pao sp QU1-18 Penetrant'can be applied by: a, brushing b. spraying c. dipping d. all of the above €. none of the above QU1-19 Fluorescent penetrants are generally because: they can flow into smaller cracks fluorescent indications are better seen by the human eye they are subject to greater capillary action aandc above band c above more sensitive than visible dye penetrants Sao gpQU1-20 Which of the following cause decreased sensitivity in PT? a. too heavy application of che developer b, cily or greasy test obje c. improper penetrant removal d. all of the above e. none of the above QU1-21 PT is limited to test objects which: a. are metallic b. are-porous c. are magnetic 4 €. are nonporous have subsurface discontinuities QU1-22 MT will discover: a. surface discontinuities b. slightly subsurface discontinuities c, underbead cracking d. aandbabove : e. all of the above Q11-23 MT is most sensitive to those discontinuities which are: a, within 45° of perpendicular to the lines of flux b. within 45° of parallel to the lines of flux c. perpendicular to the lines of flux d. parallel to the lines of flux e. none of the above Q11-24 MT is limited to test objects which: a. are metallic b, are porous c. are ferromagnetic A d. are nonporous ; have subsurface discontinuiti ° gus -25 UT is most sensitive to those discontinuities which are: a. within 45° of perpendicular to the sound waves b. within 45° of parallel to the sound waves c. perpendicular to the sound waves d, -parallel to the sound waves none of the above 2QU1-26 UT uses freque: below the range of human hearing Within the range of human hearing above the range of humen bearing beside the range of human hearing none of the above sae ge QU1-27 In UT the horizontal axis of the CRT screen gives information about: a. the distance the sound has traveled in the part b. the amount of sound energy reflected c. the type of discontinuity 4. discontinuity orientation €. discontinuity cause QU1-28 RT shows areas of lower density as: dark regions on the film light regions on the film light or dark regions on the film all of the above none of the above Pao ge QU1-29 RT shows areas of less thickness as: dark regions on the film Jight regions on the film light or dark regions on the film all of the above none of the above eRoge QU1-30 RT shows areas of increased transmission as: a. dark regions on the film b. light regions on the film light or dark regions on the film all of the above| d. €, none of the aboveQUL-31 Tungsten inclusions gencrally appear in RT as: a dark régions onthe §'m b. light régions on the fiim ©. light of dark regions cn the film q e all of the above none of the above QU1-32 Cracks generally appear in RT as: dark lines on the film light lines on the film light or dark lines on the film all of the above none of the above eS aogp QU1-33 Weld reinforcement generally appears as: a. dark regions on the film b. light regions on the film €. light or dark regions on the film d. all of the above €. none of the above QU1-34 Porosity generally appears in RT as: a. dark regions on the film b. light regions on the film ¢. light or dark regions on the film d. all of the above €. none of the above QUI-35 Shallow: surface cracks can best be detected in 308 stainless by: a UT db. c. RT d. ©, all of the aboveQUI-36 Uncerberd cracks can svg a QU1-37 Porosity : UT a b. b, c d. €, c. d. €, ET MT Ur PT all of the above MT RT PT all of the above tbe detected by: in ESW can best be detected by: QU1-38 The vertical axis of the UT CRT screen represents: a. ep aos eae ge distance time reflector size none of the above all of the above object? AET aand b above band c above QU1-39 What NDE. method(s) rely on the transmission of sound energy through the test QUL-40 What NDE mpthod(s) often rely on the application of a hydrostetic pressure to a a. b c d e. vessel? Pressure tests leak tests proof tests all of the above none of the abavebled Qil-41 What tes: beloy eDitic § a RT db. PRT c. ferrite test d. UT €. lied to determine the metallurgical effects of Welding | I | QU1-42 Application of a vacuum box to the inside surface of a Steel storage tank is one | form of which test below? VT LT 7 all of the above none of the above ease p QUI-43 FN is a unit of measurement with which test below? a, RT | b. PRT c. feizite test a. UT e, PT QU1-44 NDE personnel are normally qualified in accordance with ASME Section V AWS D1.1 ANSI SNT-TC-1A. ASNT SNT-TC-1A ASME SNT-TC-1A S RogQ12-1 eRe ge QU2-2 sags Q12-3 paos Q12-4 gags Once inspections are completed, what important aspect of the inspector's job mu:| be accomplished? ce tell the foreman that the weld is acceptable tell the supervisor that the inspection is complete fill out an inspection report detailing his findings all of the above none of the above Which of the following is not normally required of inspection reports? inspector's signature an indication of only those parts which were acceptable they should be clear and concise they should be filled out in ink none of the above “What authorship is attached to inspection report forms? the inspettor’s signature the weldér’s signature the welding supervisor's signature Forms are anonymously presented. Forms are not signed. What handy report forms are available from AWS? Appendix E of AWS D1.1 Appendis I of AWS D1.1 Appendix O of AWS D1.1 AWS QC 1 ASME N11 FormYou have made ar mistake on a report form. How should it be corrected? An experienced inspector will use a pencil so such eiors can be erased and corrected As an inspector-in-training, such errors need not be corrected. To keep the report legal and"credible, the error should be crossed out and the correction added adjacent to the error and noted complete with initials and date of correction. The report must be completely rewritten. none of the above How are errors in writing corrected in written reports? crossed out erased with an ink eraser entire page must be rewritten crossed out, corrected, initialed and dated none of the above Who is authorized to sign off ASME data report forms? the authorized inspector who performed inspection an authorized keeper of the code stamp an officer or manager of the company any of the above both a and b above How are opinions on workmanship or suggestions for repair usually reported? Comments are written in chalk on the work. by unstructured reports Provisions for such comments are contained in structured reports. Inspectors aré forbidden to offer such comments. none of the aboveChapter 1 Qui Qu-2 a3 Qi-4 Qs Qu-6 Qi7 Qu8 Qi9 QEI0 Qr-il Qniz Q1-13 Qu-14 QL1S Chapter 2 Qa Q2-2 Q23 BORD eooegTHReoaD a Chapter 3 Gl Q3-2 33 Q3-4 Gs Q3-6 Q3-7 Q3-8 Q3-9 Chapter 4 4-1 Q42 Q4-3 Qh Q4-5 Q4-6 Q4-7 04-8 Q4-9 Qe10 Q4-11 Q412 Q4-13 Qed 415 4-16 Q4-17 4-18 Q419 Q4-20 Q421 Q4-22 4-23 d eogvacose c a e © d c e b c e d ce a b © b © d a ce b e d Q4-24 Q4-25 a Q4-26 d Q4-27 & 04-28 & Q4-29 bs Q4-30 b QW31 ¢ Q4-32 a Q433 & Q4-34 b Q4-35 & Q4-36 d Q4-37 a Q4-38 b Q4-39 d Q4-40 a Q4-41 a QH42 b. 4-43 Q4-44 d Q4-45 04-46 a Q4-47 a 448 b 04-49 Q4-50 Q45id 4-52 b Q4-53 e Q4-54 Q4-55 b Q456 d Q4-57 Q458 a 4-59 be 4-60 a Q4-61 Q4-62 b Q4-63 e Q4-64 a Q465 6 Q4-66 b Q467 b Q4-68 a 4-69 Chapter 5 Q5-1 © G2 d 3 Q5-4 5-5 PoenagecnnesaenaBSS Q-26 ¢ Q9-22 a O59 Q27¢ 9-23 b Q5-24 cy QEI0 &> QU-28 a» Q9-24 b Q5-25 b QE o- Q7-29 b- Q9-25 d Q5-26 de Q6-12 a Q7-30 ev Q9-26 b Q5-27 a” Q6-13 bs QT-31 ¢ Q9-27 ¢ i Q5-28 ax Q6-14 by Qe | Q9-28 d Q5-29 dv Q6-15 bv Q7-33 a Q9-29 a Q5-30 bu Q6-16 dv Q7-34 ey Q9-30 d i QS-31 ex 6-17 &/ QU-35 a Q-31e Q5-32 a Q6-18 a Q9-32 e 5-33 b Q6-19 ox Chapter 8 Q9-33 | 5-34 ay Q6-20 ev O81 cv Q9-34 c | Q5-35 b Q6-21 b- O82 ¢ Q9-35 d Q5-36 Q6-22 © 3 Q9-36 b Q5-37 by 06-23 & Q8-4 d Q9-37 a Q5-38 6-24 ¢ Q8-5 Qo-38 e G-39 ¢, 8-6 & Q9-39 b Q5-40 b- Chapter 7 Q8-7 a’ Q9-40 a Q5-41 cy Qi a Q88 cv Qe-4l Q5-42 ¢ Q7-2 a Q89 dk Q9-42 a Q5-43 av O73 a Q9-43 d 5-44 a, * Qn4 Chapter 9 Qed a | Q5-45 bi Qs Q9-1 d. Q9-45 a Q5-46 dv Q76 ¢ 092 ¢. Q9-46 € Q5-47 ds 77 ¢ 093 ¢ Q9-47 d 5-48 c. Q78 O94 a Q9-48 d Q5-49 b. Q79 ¢ 09-5 b Q9-49 € Q5-50 a Q7-10e 09-6 ¢ Q9-50 Q5-51 cy Qrile, Qo7 & Q9-51 d Q5-52.¢ QZ a Qo-8 a Q9-52 Q5-53 a QU-13 a Qo9 4 Q9-53 d 5-54 be Qridd Q9-10 d Q9-54 Q5-55-d Qr-15 ¢ 9-110 Q9-55 & 5-56 & Q7-16 d Q9-12 d Q9-56 QriTb Q9-13 a Qos7 d Chapter 6 Q7-18 a Q914 ¢ Q9-58 d Q6-1 ev Q7-19 b Q9-15 a Q9-59 ¢ 6-2 af Q7-20 d 09-16 ¢ Q9-60 d 7 Q6-3 ¢ Q7-21 b Q9-17 ¢ Q9-61 b - Q6-4 db: Q7-22 Q9-18 ¢ Q9-62 b 7 Q6-5 e Q7-23 b Q9-19 ¢ Q9-63 € 06-6 © Q7-24 a Q9-20 ¢ Q9-64 d Q6-7 b Q7-25 e.- Q9-21 bChapter 10 Qo-1 Q10-2 Q10-3 Q10-4 Qu0-s Q10-6 QU0-7 Q10-8 Q09 Q10-10 ¢ QU0-11 a QU0-12 b QU0-13 € Q10-14 b Q0-15 ¢ Q10-16 b QO-17 ¢ QW0-18 & QU0-19 a Q10-20 b vacornonaa Chapter 11 Qui e Que d Qu3 4 Qa a QUIS c QlL6 QUT c Qu8 d QU ‘4 QU1-10 Quite Qi ide Quis a Qli-14e QUA-IS b QUI-16 ¢ QUIT d QU-8 d QII-19 b QU-20 d Quaid Qui-22 d QU1-23 © QU1-24 QU1-25 ¢ QU1-26 ¢ QU27 a QUi-28 a QU-29 a Q11-30 a QUi3r b Qu1-32 a QU1-33 b QU1-34 a QUL-35 d QUI-36-¢ QU1-37 ¢ QU-38 QU-39 QUL-40 d QU-4i c QU-42 c QU1-43-¢ QU1-44 d Chapter 12 a 2 5 a cr aom»CERTIFICATION MANUAL FOR WELDING INSPECTORS THIRD EDITION Published By American Welding Society Education Department TORE 6, BALAJADIA WAR... 31 , 2000 American Welding Society &DISCLAIMER, The American Welding Society, Inc. assumes no responsibility for the information contained in this publication. An independent, substantiating investigation should be made prior to reliance on or use of such information. TONI 6, BALAJADIA WAR 31 , 2000 International Standard Book Number: 0-87171-421-3 Copyright © 1993 by American Welding Society, Miami, Florida, Third Edition 1993 Revised 10/95 All sights reserved. No part of this book may be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage or retrieval system, without permission in writing from the publisher. Printed in the United States of AmericaIn 1976, the Amefican Welding Society introduced 2 much needed certification program specificelly for those individuals who perform visual welding inspection. Shortly thereafter, the AWS Qualification and Certification Committee initiated the development of a single publication which could serve as a valid reference for those individuals interested in becoming qualified as a Certified Welding Inspector. Prior to the initial publication of Certification Manual for Welding Inspectors in 1977, relevant information on the subject could be found scattered among Various documents such as Welding Inspection and Guide to Nondestructive Testing of Welds, Dr, Hallock C, Campbell was selected to organize existing information on the topic in a manner that would be most helpful to those individuals who wished to become better prepared for both the certification examination as well As their jobs as welding inspectors. Dr. Campbell's ability to present this technical information in a form that inspectors of many different backgrounds could easily comprehend has made the Certification Manual for Welding Inspectors one of the most utilized documents on the subject. The initial printing was followed by a revised second printing in 1979, and finally @ Second Edition, released in 1980, This is, I feel, adequate proof of the publication's value to the industry. Since’that time, humerous changes have occurred in both the AWS Certified Welding Inspector program and examination as well as the technology related to welding inspection, Conse: juenitly, the AWS Continuing Education Committee sought to update the information contained in the Certification Manual. ‘Much of the information contained herein was drawn from other AWS publications, including: Welding Inspection, Second Edition, Welding Inspection Technology, AWS B1.11-88, Guide for the Visual Inspection of Welds, and AWS B1.10-86, Guide for the Nondestructive Inspection of Welds. The reader is encouraged to review these and other documents for even more detailed descriptions of much of the information contained in this new edition. ‘As Dr, Campbell] pointed out in previous editions, welding inspectors are employed in a variety of industries. As a resullt, their duties will differ somewhat from one situation to the next. This Manual has been developed under the assumption that a welding inspector will be performing quality control duties of ‘eral nature, Some inspectors, for example, may be working et a field construction site where he or is in charge of pverall welding quality. At the other extreme, in a large organization, a quality assurance department may make meny of the decisions that the Manual assigns solely to the inspector. As noted by Dr. Campbell, in either case, the welding inspector will always perform a key role. individual inspector's specific role in the quality control activity must therefore mesh with many other ac- tivities and personnel, 2s outlined in the pages which follow.In this third edition, there has been an attempt to update the technical information, wheré appropriate, One of the areas where readers of previous editions will note changes is in the terminology used for describing various weld characteristics. There is an ongoing effort to use standard terminology when talk ing about welding operations and related weld characteristics. Other important changes incluce the addition of more illustrations and photographs to better describe much of the information, A final major ‘change involves the questions appearing at the end of each chapter. ‘The number of questions has been significantly increased to provide those individuals who are preparing for the CWI examination with numerous examples of the types of questions that appear on the test. ‘To further enhance the value of the questions, they all appear in the same format (multiple choice with five options) as the questions on the CWIexamination. While this is intended to specifically aid those studying for the test, it should also be beneficial to others from the standpoint of improving their comprehension of the information presented in the text. ‘The fourteen chapters included in previous editions have been rearranged and combined into twelve chapters, much like the AWS Course Welding Inspection Technology. It is hoped this change will result in better understanding by the reader. As with previous editions, the target audience remains the same: practical people in welding inspection, technicians, and the novice welding inspector who are not specifically interested jn a highly technical and academic treatment of the topics presented. That does not mean, however, that technical topics have been omitted; only that they are presented in a manner and Tanguage that should allow for their comprehension by individuals having a moderate amount of education and experience, T hope this presentation will prove helpful to those interested in becoming’ welding inspectors and eventually becoming qualified as an AWS Certified Welding Inspector. The.job of welding inspector is a tremendously challenging and important one, and those seeking the CW] qualification should be com- mended and encouraged. My personal desire is that this Manual will assist you in reaching that goal. I wish you the best in that endeavor, Richard L. Holdren, PE. July 1993Chapter Title Preface . Thhe Welding Inspector. Welding Inspector Responsibilities Codes, Standards and Specifications Weld Joint Geometry and Welding Terminology Welding Symbols Weldability, Welding Chemistry and Welding Metallurgy Destructive Testing sa... Welding Procedure and Welder Qualification ... OMIANUKRWONE Welding, Brazing and Cutting Processes ..... Weld and Base Metal Discontinuities .. Nondestructive Examination Processes .... mee veo Inspection Reports. Appendix A - Additional Resources & References Appendix B - Sample Forms Appendix C- Answer Key Index .... TOW! 6, BALAJASIA MAR. 31), 2900 RSIntroduction Welding Inspectors function as quality representatives of organizations that may be the manufacturer, the purchaser, an insurance company, or a government agency. The inspector is responsible for judging the acceptability of a product according fo a written specification. ‘The inspector must understand the specification both as {o its limitations and intent, Keep in mind that the goal is to strive for the required quality without delaying completion and delivery without proper cause, Welding inspectors find themselves working in dozens of different industries, with each situation having slightly different job responsibilities. | Among those industries employing welding inspectors are: energy production, chemical processing, petro- Jeum product refining and distribution, transportation, and bridge and] building construction. The welding inspector is @ composite person, a specialist, highily qualified in the field of welding, Welding inspectors can be classified as: + Code or governing agency inspector + Purchaser's, customer's, or owner's inspector + Fabricator's, manufacturer's, or contractor's inspector + Architect's or engineer's inspector Even though the in-house inspector may have different duties from the outside inspector, within this manual, only a single inclusive category of inspector is considered. Hence, the contents of this manual sometimes may apply to all the categories above or limited to one or more of them, In all cases, the inspector he’s the necessary qualifications and is competent to make the examinations appropriate for the type of weldment being inspected. ‘Crain ara corpraonImportant Qualifications for the Welding Inspector For a person to become a welding inspector, there are a number bf important qualifications, Any person who wishes to do his or her inspection job conscientiously and professionally must take these qualifications seriously. Physical Condition A welding inspector's physical condition must allow one to be an active inspector. Inspection requires examination before, during and after fabrication. Climbing around large fixtures and assemblies can be a job requirement, Inspection conditions are frequenily difficult, Work is sometimes positioned for the convenience of welders and welding operators, but not necessarily for the inspector. Short of unnecessary endangerment, the inspector must be able’ to see the weld to perform the visual inspection. Inspecting completed welds in the shortest possible time requires the same ‘means-of access to the weld that the welder had. Vision Good vision is vital. The ability to examine weld surface conditions and judge their acceptability accofding to wriiten quality requirements are the primary functions of a welding inspector. An AWS Certified Welding Inspector (CWI is required to have 20-40 vision, as determined by corrective eye charts, and Jaeger J-1 near vision acuity, with or without comective lenses. The required eye examination may also include a color perception test for red/green and blue/yellow differentiation. Color perception for most visual welding inspection jobs is not a requirement. According to AWS QC 1, "Jt is the employer's responsibility 10 determine and enforce any color perception requirement.” Professional Attitude It is extremely important that the welding inspector maintain a professional attitude. Attitude determines the degree of success or failure. Success will be dependent upon the cooperation of associates in all departments, and the welding inspector must have their respect to obtain their help. It is important that the welding inspector strive to,be impartial and consistent in all decisions, The inspector should develop a definite method for inspection procedures. Remember, the welding inspector must be neither stubborn nor readily swayed by persuasive arguments, Under no circumstances may the welding inspector seek favor or incur obligation through personal decisions or pending decisions. Knowledge of Welding and Inspection ‘Terminology The improper use of welding terminclogy by a welding inspector could create an embarrassing situation if it becomes apparent to others in job related conversations. Consequently, the welding inspector must know and communicate correctly the language of welding. The job of welding inspector requires communication of findings to the shop people, who created the welds and make repairs, and the engineers who planned the work and accept the final structure. The vocabulary used in speaking end writing must be in terms understandable to all involved Inspectors should make ready use of AWS A30, Welding Terms and Definitions, ‘The latest edition provides AWS approved terminology used to describe the various aspects of welding. It is advisable that welding inspectors study and consult the standard until the terms become part of their natural vocabulary. Included in this manual will be explanations of: types of joints and welds, parts of welds and weld application terminology (Chapter 4); terminology related to destructive testing (Chapter 7) and nondestructive examination (Chapter 11); names and descriptions of weld and base metal"discontinuities (Chapter 10); terms related to be certain the NDT technicians have the proper welding metallurgy (Chapter 6); and terminology credentials and be familiar enough with the related to various welding processes (Chepter 9). method to determine if the test results obtained ‘meet prescribed requirements. Knowledge of Drawings and Specifications ‘An inspector must be A WELDING INSPECTOR BRINGS familiar with engineering CERTAIN AMOUNTS OF KASH TO drawings and able to understand — specifications. | Welding THE JOB inspectors must be able to read and understand blueprints and drawings and must know welding and nondestructive examination symbols. It is not necessary to memorize the various standards and specifications that may be in effect. Rather, they should be available for reference whenever the welding inspector needs information contained in these documents. The welding inspector should be familiar with the contents so that it doesn’t take Jong to find information, of crawingt Knowledge of welding terme nowiedge of webaing procates Knowledge of tsting meihocs Asiey te Good physica! condition Good vision Training in engineering sng metaletsy napaction experience Knowledge of Testing Methods Numerous destructive and nondestructive testing methods are available for use in determining whether a base metal, weld metal, and/or a weldment meets - certain specification requirements. ‘While perhaps not performing the testing, the welding inspector must be aware of the test basics, including: application technique, obtainable information, and the advantages and limitations. If others are performing the tests, the welding inspector must L——_—_1-4 Ability to Produce and Maintain Records A welding inspector should be ‘able to develop and maintain inspection records. He must be able to write concise, accurate reports. The report should be simple and understandable to anyone familiar with the project. Reports should, at the same time, be complete enough so that the reason for decisions will be clear months or years later. It is important to remember that well-known facts at the time of the writing often are not, remembered as clearly, completely, or accurately Jater. Records should include not only all results of inspections and tests but also supporting records relating to: welding procedures, welder qualifications, drawing or specification revisions, ete. Good records also protect the welding inspector's reputation, Knowledge of Welding Processes Since the welding inspector spends the major portion of his time evaluating welds, knowledge of the various welding processes is essential Further, actual experience as a welder or welding operator is valuable to a welding inspector, but is not mandatory. Welding experience broadens the inspector’s welding knowledge, commands respect, end gives his opinions more credibility when weld quality is being evaluated. There are some employers who require actual welding experience as a prerequisite to becoming a welding inspector; however, welding experience is not a prerequisite to certification as an AWS CWIorCAWI. The inspector who is familiar with the advantages and limitations of the various welding processes is able to identify problems when, or even before, they occur. Ability to be Trained Welding inspectors are expected to possess knowledge in a number of different areas to be considered effective, and to be trained in areas of unfamiliarity. Many employers select persons as potential welding inspectors based on their ability to study and gain the necessary knowledge. Training in fundamental engineering can apply toward partial satisfaction of the experience requirements for becoming a CWI, AWS QCI, Standard for Qualification and Certification of Welding Inspectors outlines these limits for the CWI program, Inspection Experience Only through inspection experience is the attitude and point of view of a good inspector acquired. Even experience in inspecting unwelded materials is extremely helpful in the inspection of weldments, since a good inspector has developed a distinct way of thinking and working. Those Jearning the ropes should observe the behavior and techniques of experienced inspectors. To comply with the experience requirement for AWS certification, the welding inspector must show evidence of having performed the functions of a welding inspector. Other job functions that have a close relationship to welding inspection also provide this evidence. Periods of qualifying experience are counted by the actual number of calendar months employed at jobs (not the number of employers). The jobs must have a close relationship to fabrication of weldments according to a code, standard, or specification, and directly involve one or more of the following: + Design: Preparation of plans and érewings for weldment construction/fabrication. + Production: Planning and control of welding materials, welding procedures and welding operations for weldment fabrication. * Construction: Fabrication and/or erection of weldments.+ Inspection: Detection and measurement of weld discontinuities; verification of fabrication yequirements, as described in Section 4.2 of AWS QCL + Repair: Repair of welds that are defective, Ethical Requirements for the Welding Inspector Introduction This manual will discuss the technical methods, procedures, processes, and functions of the welding inspector, However, effective weld inspection requires not only the performance of duties consistent with the specification requirements, but also the practice of professional conduct and ethickl principles. Below is the “Code of Ethics” for welding inspectors, which is included in AWS QCI, Standard for Qualification and Certification of Welding Inspectors. The latest edition of AWS QC1 should be consulted for the most recent requirements. Preamble Jn order to safeguard the public's health and well-being and to maintain integrity and high standards of skills, practice, and conduct in the ‘occupation of welding inspection, the AWS Cer- tified Welding Inspector (CWI) and Certified Associate Welding Inspector (CAWI) shall be cognizant of the following principles and the scope to which they apply, with the understanding that any unauthorized practice is subject to the AWS Qualification and Certification Committee's review and may result in suspension, repsimand or revocation of certification, Integrity ‘The CWI and CAWI shall act with complete integrity (honesty) in professional matters and to 15, be forthright and cendid to the Committee or its representatives on matters pertaining to AWS cL Responsibility to the Public The CWI and CAWI shall act to preserve the health and well-being of the public by performing the duties required of weld inspection in a conscientious and impartisl manner to the full ex- tent of the inspector’s moral and civic responsibility and qualification. Accordingly, the CWI and CAWI shall: + Undertake and perform assignments only when qualified by training, experience and capability + Present credentials upon request. + Neither falsely represent current status nor seek to misrepresent certification level (CWI/CAW]) by modification of certification documents false verbal or written testimony of current level or status. Toney Standard Clee Certification . of Welding” Inspectors+ Be completely objective, thorough and factual in any ywritten report, statement or testimony of the work and include all relevant or pertinent testimony in such communiques or testimonials + Sign only for work the inspector has inspected, or for work over which the inspector has personal knowledge through direct supervision. + Neither associate with nor knowingly participate in a fraudulent or dishonest venture Public Statements ‘The CWI or CAWI shall issue no statements, criticisms or arguments on weld inspection matters connected with public policy which are inspired or paid for by an interested party, or parties, without first identifying, the party, the speaker, and disclosing any possible financial interest. ‘The CWI or CAWI shall publicly express no opinion on welding inspection subjects unless itis, founded upon adequate knowledge of the facts in issue, upon a background of technical competence pettinent to the subject, and upon honest conviction of the accuracy and propriety of the statement, Conflict of Interest ‘The CWE or CAWI shall avoid conflict of interest with the employer or client and will disclose any business association, or circumstance that might be so considered, The CWI or CAWI shall not accept compensation; financial or otherwise, from more than One party for services on the same project, or for services pertaining to the same project, unless the circlimstancés are fully disclosed and agreed to by all interested parties or their authorized agents. ‘The CWL or CAWT shall not solicit or accept gratuities, directly'‘or indirectly, from any party, or parties dealing with the client or empleyer in connection with the CWI's and CAWY's work. ‘The CWI or CAWI shall, while serving in the capacity of an elected, retained or employed public official, neither inspect, review nor approve work in the capacity of CWI or CAWI on pro- projects ‘also subject to his administrative jurisdiction as a public official, unless this practice is expressly dictated by a job description and/or specification and all affected parties to the action are in agreement. Solicitation of Employment “The CWI and/or CAWI shall neither pay, solicit, or offer, directly or indirectly, any bribe or commission for professional employment with the exception of the usual commission required from licensed employment agencies. The CWI and/or CAWI shall neither falsify, exaggerate, nor indulge in the misinterpretation of personel academic and professional qualifications, past assignments, accomplishments, and responsibilities, or those of the inspector's associates. Misrepresentation of current CWICAWI certification status at the time of, or subsequent to, submission of requested employment information, or in the solicitation of business contracts wherein current certification is either required or inherently beneficial (advertisements for training courses, consulting services, etc.) shall be a violation of this se ‘The CWI and/or CAWI shall not function as an independent inspector in public fields out of his or her capability, without first investigating for possible industry or public requirements and additional education/experience requirements (e.g., industrial labs, in the concrete and soil testing field, etc.). CAUTION: While the CWT has established excellent credentials, certification alone may net legally qualify the Inspector to provide inspection services to the public. Contract documents,Building or Jurisdiction Laws may require inspection to be performed under the direction and responsibility of others, such as ¢ Registered Professional Engineer. Unauthorized Practice Any violation of any part of the standard of conduct prescribed by AWS QC1 if related to a CWI’s or CAWI’s occupation, including any violation of the Code of Ethics contained in AWS QCI, shall constitute an unauthorized practice subject to the imposition of senctions. Establishing Lines of Communication The welding inspector must possess the physical, technical, and ethical qualifications mentioned earlier, as weH as the skill of a communicator. The welding inspector's success will be affected by his ability to convey information to others as well, as understand what others are trying to explain. Communication can occur in numerous forms, including: spoken words, written wards, pictures, numbers, or gestures. Each provides an effective means of conveying information. The inspector should always be cautious regarding verbal communication. If is often important to have verbal communication supported by written information, especially when it relates to changes in the inspection requirements or results. Any form of communication should be a continuous loop. That is, the receiver should have the oppor tunity to respond to the sender. Effective communication must be considered es a two-way proposition, ‘The welding ingpector ofien finds himself es the central figure in many fabrication situations; consequently, he must be capable of communicating effectively with many individuels involved in the project. The welding inspector must be able to establish lines of communication with a varied number of associates to accomplish 17 THE WELDING INSPECTOR — A COMMUNICATOR SPEAKS. WRITES ACTS DRAWS MESSAGE WELDS {SPOKEN WORDS svVRITTEN WORDS. SENDER — srictunes ECEIVER onuMBERS LISTENS, READS nesraneeto Shoen FF = OBSERVES INFERS INSPECTS the necessary tasks and responsibilities efficiently and professionally. For example, the associates of a fabricator’s inspector will often include the following: Reporting Supervisor Virtually all welding inspectors will report to someone; in some cases, it will be the chief inspector, In other sitwations, it could be the project engineer, a plant manager, an architect, or government official. Regardless of who this individual is, the welding inspector should be able to refer questions or job difficulties to him for answers or guidance. Through effective communication, thet supervisor should be able to help the inspector become more knowledgeable of the job, and therefore more effective.‘Welders ‘The relationship betwen the inspector and the welder is of utmost importance. The welder often knows which welds are of borderline quality. The welder may know where the joint fitup was improper or not as specified. A welder who looks con the inspector as an enemy is not concentrating on making each weld a good one. At any rate, he will not be trying to make the inspector's job any easier. In most cases, good rapport between the welder and inspector will result in improved quality and higher efficiency because problems are identified and corrected when they occur instead of later ao ce when re- weonoaneneen pairing it is ESTABLISHING costly. LINES OF COMMUNICATION Welding Foremen a or Super: visors 4 The weld-7\, ing foreman or!¥tetrs supervisor is highly - important to the inspector. Given a group of welders equally qualified to meet specificetions, the foreman still decides which welder is best suited for more difficult welding jobs. Both the welding inspector and the foreman should be in agreement as to which welders are considered quelified to produce satisfactory welds. At times, the fabricator’s representative may suggest that the welding inspector tell the. welder what he wants. This would make the welding inspector a party to the operation, and perhaps eliminate the fabricator's responsibility to meet the specification require- meats, Remember, the inspector's authority extencs only to the determination as to whether the weld is acceptable or rejectable. Volunteering unsolicited information may overstep an inspector's responsibility and should therefore be limited, ‘These supervisory people are also concerned with production, s0 some communication must occur to indicate when parts or assemblies will be ready for inspection. After that inspection, they will need to know if the welding has been found to be acceptable. If rejects are noted, then more communication will be necessary to describe and locate the defect so that repairs can be accomp- lished. fgets Shop or Field Super- intendent There may also be the need to discuss weld qual- ity matters with the shop or field super- < ferent intendent. This is most likely because some aspect of the welding quality is having an effect on the overall production schedule of a project. In other cases, the welding inspector may simply have encountered some problem which is, beyond the responsibility of the welding foreman or supervisor. Plant Manager Communication with the plant manager is much the same es that with the shop or fieldsuperintendent. They are responsible for production, 2s well es the product quality, Consequently, they are very concerned about Teaming whet the s:atus of some part may be when it is subjected to| inspection. A single rejected weld could result in delays for the entire project. ‘The welding inspector needs to keep him informed 0 he is aware of the acceptability or rejectebility of some item so appropriate scheduling can be accomplished. Design/Project Engineers ‘The design engineer is responsible for the details of any welded fabrication. His intentions are communicated through drawings and specifications. The project engineer is then responsible for the interpretation of these requirements when the work is being performed, ‘The welding inspector may need to communicate with both of these individuals regarding these welding requirements. An overview. of the job in consultation with the project engineer will bring out any fabrication or inspection tasks thet may require additional planning. For example, in a massive, complex weldment, weld sequencing may be necessary to assure weld soundness and minimize distortion, or some design detail may need modification to facilitate, successful ~ fabrication and inspection, Welding Engineer The welding inspector should have access to the welding engineer, welding technician or welding specialist so that possible welding-related construction problems can be brought to his attention before they become inspection problems. The welding inspeptor can be thought of as the welding engineer's “eyes” as the welding is being performed. When such an arrangement exists, the welding inspector can communicate with the welding engineer to describe fabricetion problems $0 that corrective action can be instituted. Proper communication is importent to the inspection process, The welding inspector's primary function is to inspect the fabricator's work to see that it meets the requirements of the contract. The quality of work being accomplished is the sub- stance of the welding inspector's reports. Whether the fabricator takes advantage of this information may depend upon how clearly it has been presented in the report. The fabricator still has full responsibility for the quality of the final product, Proper communications will allow the welding inspector to keep in touch with the activities of the production organization. Early correction of a fault resulis in producing a satisfactory product instead of one that would otherwise have to be rejected and subsequently repaired. Summary ‘The job of welding inspector requires a wide variety of talents and physical capabilities. The individual must be both mentally and physically prepared for the many tasks at hand. The inspector's day-to-day existence dictates that he has the proper knowledge and training, can accurately report his findings and maintain that information for future reference, and can conduct himself in an ethical manner. Good welding inspectors are invaluable to a company. When permitted to act as specified by an effective quality control system, the weldi inspector can often save a company money by identifying problems when or before they occur to minimize correction costs.Introduction The welding inspector holds a position of responsibility. This responsibility demands a professional person with good character, ability, and common sense. A welding inspector may work at various fabrication plants and at vatious ob sites. In all cases the welding inspector should observe the working hours of the fabricating organization. Strict observance of all rules and regulations especially those pertaining to personal conduct, safety, and security are mandatory. Never should the welding inspector consider himself entitled to special privileges. In dealing with the fabricating brganization, the welding inspector should be impartial, render decisions promptly, and be tolerant of the opinion of others during communications. Remember, however, to stick to the facts when making decisions. Do not be easily swayed by differing opinions. ‘To perform visual inspection effectively, it is necessary to observe ns many of the individual stages of fabrication as possible, Consequently, the various responsibilities of the welding inspector are categorized when they occur, specifically: before, during and after welding. ‘Typical inspection requirements might be: Inspection Responsibilities Before Welding + Review all applicable drawings and standards. * Check purchase orders to ensure that base and filler materials are properly specified + Check and identify materials as they are received against the purchase specifications, + Check the chemical compositions and mechanical properties shown on mill test reports against specified requirements. + Check the condition and storage of filler metals + Check the condition and adequacy of ‘equipment to be used. + Check weld joint edge geometries + Check joint fit * Check joint cleanliness, + Check the welding procedures and welder qualifications, + Check preheat temperature. Inspection Responsibilities During Welding + Check welding parameters and technique for compliance with welding procedure. + Check quality of individual weld passes. + Check interpass cleaning. * Check interpess temperature, + Verify that in-process NDB is performed, if required.Inspection Responsbes Aer Welding + Check finished Weld appearance. + Check finished weld sizes and lengths. + Check dimensional accuracy of completed weldment. + Select production test samples. + Byaluate test results, + Verify that additional NDE has been performed, if required. + Verify that postweld heat treatment has been done satisfactorily, if required. + Prépare and maintain inspection reports Inspection Responsibilities Before Welding Knowledge of Drawings and Standards Drawings, designs, standards, contracts, etc., should be studied in advance so that the welding inspector is aware of the construction details, the proposed use of subassemblies, and the specifics of the welding operation. Note which materials are to be used in the welded structure and whether any of them require special treatment for satisfactory welding. This information should be clearly stated in the standards or welding procedures. If it is not there, the project engineer should be contacted for'clarification. During febrication of e welded structure or component, the welding inspector may be called upon to interpret drawings or standards on the spot. Prior study of the drawings and design requirements will enhance one's ability to make clear and concise decisions. Clear and concise decisions will speed completion of the work under contract, increase the inspector's professional imege, and greatly aid in exercising authority. Situations that require deviation from the drawing or detailed standard may arise during the fabrication of any structure. It is the welding inspector's responsibility to alert the project engineer or quality assurance (QA) personnel. They will decide whether the deviation in question should be permitted or rejected. Sometimes acceptance or rejection of a large welded structure will be involved. It may be the inspector's duty, after careful study, to recommend whether the error can be corrected and whether the method of correction to be used will still insure a satisfactorily completed product in accordance with the drawings and standards. In all cases, he should exercise extreme caution in accepting deviations. Deviations from drawings should be referred to the design agency for approval, Their approval should be received “in writing.” It is not always possible to write an all- inclusive standard containing all the'detailed information needed to provide an answer for. any question that might arise, If parts of the standard have requirements thet are not fully defined, the inspector is often responsible for determining the meaning and intent of that document Communication with engineering and design personnel may be necessary before responding to a fabricator. Purchase Specifications Check The specifications for the job should identify all. the materials that will be used. This should include all consumable material such as welding electrodes, welding or brazing fluxes, shielding gases, consumable inserts, and backing bars or rings. The inspector should review the purchase order or contract to see that the materials ordered meet the specification requirements. For example, commercial specifications for steel, such as ASTM AS72, frequently include more than one grade of the product, which must be individually identified on the purchase order to obtain the correct grade,for welding interchangeable when low hydrogen grades sre adozen required. If low hydrogen types are required, either E7015, E7016, E7018, or E7028 must be on the purchase order. ‘As another example, specificatio: electrodes, such as AWS AS.1, \ or more electrode classificatio: document. In AS.1, the six B70XX electrodes ate all equivalent in strength, but they are not entero + 48" Flonge R saw 3? & SAW) SAY Denotes Submerged Ate Weld, cS oy $1989 ANNUAL BOOK oF ASIM STANDARDS cre Mer tcvaseoaetiee Job Material Verification ‘Mistakes do happen. Many metals look alike, leading to the possibility of inadvertent mix-ups. To prevent this, the inspector must verify that the materials supplied match the applicable purchase order, when received. In some cases, there are additional requirements for marking the proper identification visibly on each piece, preferably at multiple locations. Identification is lost for the rest of the plate if the first slice cut off by the shop removes the labeled end with the grade stamp on it. Good practice calls for remarking remnants produced in cutting operations prior to the actual cutting while the identity is still verifiable. Identification of low hydrogen welding electrodes is sometimes lost when stockroom clerks prematurely remove electrodes from their containers to store them in holding ovens. The individual electrodes will still bear classification numbers on their coverings (at the stub end), but the manufacturer's control number only appears ‘on the now discarded container. In nuclear and other critical work, that manufacturer's control number mey be needed for each weld. The preferred container for a welding electrode is its original unopened package, or stored in its opened package in an oven or suitable location. Chemica! Analysis and Mechanical Properties Tests Confirming tests of incoming materials are desired for many reasons. The number of tests required will depend on the inspector's judgment and past experience, unless everything is called out under quality assurance procedure requirements. If the material is in question, the inspector should request tests on representative samples of critical incoming materials to verify chemical composition and mechanical properties Where material test reports from reliable suppliers (that is, suppliers accredited through an approved quality assurance program) give assurance of conformance, the welding inspector should ask for check tests when errors are strongly suspected. Base Metal Defects Investigation The quality of mill products supplied for a Jjob must equal or exceed the quality specified for the final weldment or structure, Base metals almost always contain many small discontinuities. ‘Their effect depends on the thickness of the metal, the type of loding and the criticality of the design. In some instances, they may be cause for rejection; while in other instances, they may not. The welding inspector has the responsibility to see that discontinuities in the base metal are detected, identified, evaluated, and repaired properly, where necessary, so that they will not be incorporated into the welded product. That requires that the inspector be aware of the acceptable limits for these discontinuities. At times there may be a need to communicate with the responsible engineer in deciding what to do about a major defect. Some specifications may require that a defective piece be rejected and replaced unless i can be repaired. In fact, some defects may requirerejecting tne piece a'together, On the other hend, minor repeirs such as flame straightening of members cecidentclly bent in shipping or handling may be permitted by the specification, As another ‘example, the presence of laminations will rule out placing that plate where it must withstand tensile stresses in the through thickness direction, but other locations can be found where the same plate may be used with complete safety, Enginecring should make that decision. The welding inspector must then inspect any replacement materials, Condition and Storage of Filler Materials Check The welding inspector should check the condition of filler metals to be used. This is CUSTOMER TECNIWELD, INC. PURCHASE ORDER__4563, DESCRIPTION 13/4 THK. 2 3 4, PROPERTIES 4 2 CERTIFICATION OF TESTS JOPCS, 39-1/2.0.D. X 9-9/8. D. TEMP. SPECIFICATION: ASTW-A-516 GR.70_PVQ-FINE GRAIN RECE Lye; D MAY 4 19 1999 SHIPPED__5:14-90 3 4 near wo.[__eizoe | c aN BRB viewopsi| 482K Tenstersi| _763KsI ELONGATION! 8" 25.0 ‘RED OF AREA BEND TesT -KOCORDANCE WI THE APPLICA ‘SWORN TO AND SUBSCRIBED BErone we THis. bavor Ee To fewoere wwe neni cennry nd hig sve wat enms eave ezen nareoreo Ro TesTeON SPECIFICATION AND THAT TAEAQOVE FIGURES APE annette cOnra jipentconos or ts cour ae GENERAL STEEL SHEET & PLATE, INC. 2 Eo ANYTOWN, U.S.A. By___2. 2 tenagen ‘Typleal Exemple ofa Mil Test ReportPLATE LAMINATION especially true in the case of shielded metal arc welding electrodes that have a flux coating that can-be easily damaged. Other types of filler metals that may be stored out in the open could also deteriorate with time. For example, solid wire and flux cored electrodes can develop rust, which Ould result in the produétion of porosity in the weld. When low hydrogen type shielded metal are welding electrodes are being used, they must be stored in electrically heated, vented and thermostatically-controlled storage ovens to maintain their low moisture content once they have been removed from their shipping containers Besides these filler metals, some fluxes and flux cored electrodes also require special protection from moisture, whether it be rain or high humidity. Some submerged are fluxes even require heated storage containers ELECTRODE OVEN Welding Equipment Check 3 All welding equip- ment, including that to be used for testing, should be checked periodically for operational capability, calibration, and safety. For example, always check the ammeters and voltmeters if present. These meters on welding machines may not always be accurate because of mistreatment, shop contamination, and overloads, Periodic calibration is recommended. The equipment should also be checked to make certain it has the necessary output capacity to satisfy the welding procedure requirements. Welding leads, gas hoses and wire feed apparatus must also be examined to ensure their good condition and operability, Weld Joint Edge Geometry Check Specific tolerances are listed for weld joint edge geometries in various codes and specifications, The prequalified joints found in Section 2 of AWS D1.1 are typical examples. Inspection responsibilities include examination of the unwelded joint for edge geometry, including root face dimensions and groove angles. The suitability of the joint for the welding process to be used will be discussed in greater detail in Chapter 5, Weld Joint Fit Check Again, looking at the unwelded joint, the welding inspector should observe the fit of the paris, For buit joints, alignment and root opening are important. Keep in mind that prestressing or cambering may be needed for welds that will be subject to distortion as a result of weld shrinkage stresses. ‘The fabricator should not attempt such welds without the necessary knowledge.Inspector Checking Equipment Procedure modifications may give an acceptable weld, but the welding inspector may offer iggestions to the project engineer, not to the ‘man. If the foreman kater says, “You told me to do it this way.” the inspector has more difficulty in turning down an unacceptable result The fit of backing preparations needs particular attention. Backing bars and rings should fit tightly against the pieces to be joined. Transverse joints between segments of a backing aterial are undesirable, because they induce king in the root pass. For this reason, when welding in accordance with AWS D1.1, steel backing on groove welds is required to be made continuous for the entize length of that backing member cr Weld Joint Cleanliness Check In welding, the cleanliness of the base metal surfaces in and adjacent to the joint is a critical factor. Welding over contarainetion such as oil, grease, paitt, moisture, must, etc. will likely result in porosity in the completed weld. In many cases, this contamination could elso lead to the occurrence of incomplete fusion, or even cracking. Consequently, it is imperative that the welding inspector check the cleanliness of the weld zone prior to welding. Welding Procedure Qualification Check The fabricator must pre-scribe the details of the welding procedure that will be followed in producing weldments. They should produce welded joints with acceptable mechanical properties as required by the particular specification or code. Chapter 10 of this manual describes the basic elements of a welding procedure specification, the reasons for its use, its qualification, and your responsibilities as welding inspector in verifying proper application of the welding procedure on the job. Welder Qualification Check Codes and specifications thet apply to the fabrication of weldments usually require qualification of all welders and welding operators. tis the welding inspector's duty to verify that every welder and welding operator who works under the code or specification has been properly qualified in accordance with those requirements. Verification can be made either by personally witnessing each test or a review of verified tes! results. It is important for the welding inspector to monitor the welders and welding operators to ensure that they are working within the scope of their qualifications with respect to such variables as: base metal type and thickness, position of welding, welding process, electrode type and size, ete.Nan Inspector observing welder qualification testing, Welding codes and specifications do not normally require requalification of procedures, welders or welding operators for each new contract or design, ‘The welding inspector should review the requirements of the contract specification or code 10 make this determination. Remember that the main objective 6f qualification tests is to insure that procedures and welders or welding operators are adequate for the intended purpose. To be fair to the fabricator and purchaser, the inspector should make every effort to avoid unnecessary qualification tests. Preheat Check Most codes and speci- fications require that certain materials are preheated prior to welding. In Chapter 6, there is a discussion of some of the reasons why preheat is necessary. For carbon steels, preheat will be required as the base metal alloy content or thickness increases. Most often, preheat temperature is verified using temperature indicating crayons that are Temperature | Tote en asoaes tanment EImESCe CEOS ENE ETEUEELET, formulated to melt at the temperature noted on their coatings. However, digital contact pyrometers are an effective alternate. Since preheat is necessary to prevent degradation of the base metal properties during the welding operation, the preheat temperature should be measured approximately 1 inch from the edge of the weld preparation, unless the part is greater than 3 inches in thickness. In that case, the temperature measurement should be made at a distance from the weld approximately equal to the part thickness. Normally, the temperature should be maintained during all welding of the joint, For most carbon steels, the preheat is specified as a minimum. However, for some types, such as the quenched and tempered steels, the preheat temperature is expressed as a range of temperatures having a minimum and maximum value. Taper GaugeERELEL LED RERRILIL ES 2 SEEM a REE EDI ELSE 29 Tempersture Sensitive Crayon for Measuring Metal Temperature Welding Inspector Responsibi Welding In order to continue the ongoing welding quality control, the welding inspector has numerous items to check as the welding is actually being performed. As was the case for inspections performed prior to welding, these checks can hopefully detect problems when they occur so they can be more easily corrected, During this phase of the fabrication process, the inspector's knowledge of welding will be extremely beneficial, since part Of the inspection will involve the evaluation of the actual welding technique as well as the resulting weld quality. It is realized that it is unrealistic 10 think that the welding inspector cen observe the deposition of each and every weld pass. Therefore, the experienced welding inspector should be able to select those aspects of the es During ‘welding sequence which are considered to be eriti- al enough to warrant his presence. Following axe some of the aspects of this pliase of visual welding inspection which you may need to perform. Check Production Welding for Compliance with Welding Procedure When conducting welding inspection during the production welding, the inspector must rely on the welding’ procedure to guide that inspection. This document will specify all of those important aspects of the welding operation, including: welding process, materials, specific technique, preheat and interpass temperature, plus any additional information which describes how the production welding should be performed.AS SSSR SEE SEG EL TE ROE FEN ET LES SE EELEEE ES BEET] | Checking the in-process quality is especially critical in the case of the root bead. In most situations, this portion of the weld eross section represents the most difficult welding condition, especially in the case of an open root joint, In conditions of high restraint, the shrinkage stresses from welding may be sufficient to fracture the root pass if it is not thick enough to resist those stresses. The welding inspector should be aware of these problems and thoroughly check the root pass prior to any additional welding so that any irregularities can be found and corrected when they occur. Check Interpass Cleaning Another feature which should be evaluated ©} during the welding operation relates to cleanliness ‘Tong Test Ammeter The welding inspector's job will essentially consist of monitoring the production welding to assure that it is being performed in.accordance with the appropriate procedure. Check the Quality of Individual Passes One of the aspects of the welding inspection during production welding is the visual examination of the individual weld passes as they are deposited. At that time, any surface discon- tinuities can be detected and corrected, if necessary. It is also important to note any weld profile iregularities which may hinder subsequent, welding. An example of such a situation may occur during the welding of a multipass groove weld, If one of the intermediate passes is deposited such thet it exhibits @ very convex profile Which creates e deep notch at its toe, that configuration may prevent a subsequent pass from properly fusing at that location, If noted, the welding inspector could ask that some grinding be done to assure that thorough fusion can be attained on the next pass, of intermediate weld passes. If the welder fails to thoroughly clean the weld deposit between in- dividual passes, there is a possibility that slag inclusions and/or incomplete fusion could result ‘This is especially critical when using a welding process which uses a flux for protective shielding However, careful interpass cleaning is still recommended for those processes using gas shielding, Proper cleaning may be hindered when the deposited weld exhibits a convex profile which prevents sufficient access to the slag coating. As indicated above, it may then be necessary to Iperform additional grinding to remove the objectionable profile and facilitate proper cleaning, Check Interpass Temperature For welding procedures requiring interpass temperature control, the welding inspector may need to monitor this aspect of the process. As with preheat, the interpass temperature could be specified as a minimum, maximum or both. ‘The interpass temperature is also measured on the base metal surface near the weld zone, Devices such as emperature indicating crayons and surface contact pyrometers are used for these measurements, In-Process Nondestructive Examination For some welds, there may be a requirement for other types of nondestructive examitiation other than visual examination, This testing mey occur at various stages during the production of welds. For example, it is common for the root ass to be evaluated using magnetic particle ot enetrant testing to assure that itis free of stirface discontinuities or cracking, Discovery of Problems at this time will result in a relatively easy and inexpensive repair compared to that required if the problem were not detected until the weld was completed Nondestructive examination operations shall be performed by an individual qualified in Cross-sectono! partial penetration groove weld with heavy slag Inclusion 244 accordance with the recommendations of ASNT’s “SNT-TC-14," or equivalent. If the welding inspector has this qualification, he can perform this inspection as well as the visual exeminetion However, often a separate NDE technician will Perform the nondestructive test. The welding inspector is required to verify that the proper test has been administered and the results have been properly recorded. Welding Inspector Responsibilities After Welding Once a weld has been completed, the welding inspector must examine the finished product to assure that all preceding steps have been Performed to produce a quality weld. If ell of the preliminary steps have been performed as Tequired, the postweld inspection should simply confirm that the weld is of sufficient quality and size, However, the codes specify the required attributes of the finished: weld, so the welding inspector must examine the weld visually to determine if those requirements have been met, Some of the important features of this post-weld inspection are discussed below. Check Final Weld Appearance In general, visual inspection after welding consists of looking at the appearance of the finished weld, This visual examination will detect surface discontinuities in the weld and adjacent base metal Of special importance during this aspect of the welding inspection is the evaluation Of the weld’s profile. Sharp surface irregularities could result in premature failures of a component during service or create difficulty in film interpretation if the weld is to be radiographed, These visible features are evaluated in accordance with the applicable code which will describe the permissible amount of a certain type of discontinuity.