aws_welding inspection tecnology workbook_ed 5

WELDINGINSPECTION

TECHNOLOGYSample CWI

FundamentalsExamination

FIFTH EDITION

Published ByAmerican Welding Society

Education Services

+ AmericanWelding SOCielll

International Standard Book Number: 978·0·87171·663·7American Welding Society

550 N.W. Leleune Road, Miami, FL 33126© 2006 by American Welding Society

AII righls reservedPrinted in the United States of America

Fiflh Edition 2008

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Welding Inspection TechnologyFundamentals Examination

F1 Which of the following metals cannot be efficiently cut with OFC?a. high-carbon steelb. low-carbon steelc. stainless steel

d. cast irone. c and d above

F2 Electrical conductivity of a part is the primary requirement for which NDE method?a. ETb. UTc. PId. RTe. YT

F3 The melting point of carbon steel is approximately:a. 22S0°Fb. 237soFc. 2780°Fd. 300soFe. 3333°F

F4 Decibel is a term associated with which NDE method?

a. UTb. RTc. MTd. PIe. ET

F5 Which GMAW metal transfer mode results in the least amount of penetration?

a. globularb. short circuitingc. sprayd. pulsed spraye. globular spray

F6 Which of the following gasees) is commonly used as a shielding gas for GTAW?

a. argonb. carbon dioxidec. oxygend. argon/carbon dioxidee. Tri-mix

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F7 NDE technicians are certified in accordance with:a. AWS 01.1b. APIII04c. ASNT SNT-TC-IAd. ASME Section VIe. ASME Section IX

F8 When a metal is alloyed, how are the atoms of the alloy incorporated into the original metallattice structure?a. by inelusion or exelusionb. substitutionally or interstitiallyc. by dissolvingd. by becoming martensitice. by casting

F9 A wire IQI is used in which NDE method?a. UTb. ETc. RTd. MTe. PT

F10 In general, which of the following is not commonly used as a semiautomatic process?a. GMAWb. FCAWc. SMAWd. SAWe. MIG

F11 Items to be monitored by VT after welding inelude:a. extent of weldingb. final weld appearancec. dimensional accuracyd. amount of distortione. all of the aboye

F12 Crater cracks are most often the result of:a. improper techniqueb. improper filler metalc. improper base metald. trapped slage. trapped hydrogen

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F13 The tail of a welding symbol should not be used for:a. denoting welding process requirementsb. denoting welding procedure requirementsc. denoting welding electrode requirementsd. denoting welding specification requirementse. denoting groove angle

F14 During tempering, as the temperature increases, which of the following are correct?a. hardness increasesb. hardness decreasesc. elongation decreasesd. strength increasese. ductility decreases

F15 In GMAW, the distance from the end of the contact tube to the arc is:a. arc lengthb. electrode extensionc. stickoutd. stand offe. work angle

F16 Of the following, which is not a type of metal transfer in GMAW?a. sprayb. short circllitingc. globulard. plllsed arce. open circuiting

F17 Ultraviolet light may be used with which NDE methods?a. VTand UTb. PT and UTc. MTand PTd. RT and UTe. ETand MT

F18 The technique which does not aid in reducing residual stress is:a. peeningb. vibratory stress reliefc. thermal stress reliefd. external restrainte. preheating

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F19 Which of the following may not be detected with VT?a. large surface crackb. undercutc. overlapd. underfille. Lamellar tear

F20 Heat treatment conditions can be determined using which of the following?a. MTb. PTc. ETd. RTe. LT

F21 Which of the following elements are commonly used as alloying elements with tungsten toproduce GTAW electrodes?a. cesiumb. thoriumc. columbiumd. vanadiume. chromium

F22 For single bevel-groove weld symbols, the line of the AWS weld symbol running perpendicularto the reference line is always drawn on which side of the weld symbol?a. on the rightb. on the leftc. on either side. depending on company policyd. on the side in which the straight side actually appears in the jointe. does not matter

F23 The portion of the groove face within !he joint root is called:a. weld interfaceb. faying surfacec. groove weld edged. root facee. groove angle

F24 NDE technicians are usually qualified in accordance with the requirements of:a. AWSDI.Ib. APIII04c. ASNTSNT-TC-lAd. ASME Section VIIIe. ASME Section IX

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Welding Inspeclion TechnologyFundamenlals Examinalion

F25 Which of the factors Iisted below has the least amount of effect on the residual stress anddistortion that results from welding?a. heat inputb. metallurgical phase changesc. welding positiond. tensile strengthe. coefficient of thermal expansion

F26 Capillary action plays a role in which NDE method?a. ETb. VTc. RTd. PTe. MT

F27 Which of the following tests would be least effectiye for judging the soundness of a weld in theas-welded condition?a. nick breakb. side bendc. face bendd. radiographye. straight beam VT

F28 Arc blow cannot be caused by:a. magnetic field distortionb. improper worklead (ground) locationc. welding at the end of a jointd. welding in cornerse. welding with AC

F29 Which of the following shielding gases is used for GMAW spray transfer on steel?a. carbon dioxide-IOO%b. argon-IOO%c. helium-IOO%d. oxygen-2%, argon-98%e. argon 75%, carbon dioxide-25%

F30 Which discontinuity below will proyide the sharpest MT indication?a. surface porosityb. surface crackc. subsurface porosityd. subsurface cracke. indications will be identical for all of the aboye

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Welding Inspeclion TechnologyFundamentals Examinalion

F31 In SMAW, an increase in arc length results in:a. increased current; increased yoltageb. decreased current; increased yoltagec. increased heat input; decreased yoltaged. decreased current; decreased yoltagee. decreased current; increased heat input

F32 Weld inspection reports should always:a. be completed in ink, or typewritten and signedb. be done in pencil so mistakes can be easily correctedc. be filled out only if the weld is rejectedd. be typed by a clerk so that eyerything is readablee. inelude the welder's identification

F33 The ability to be cyelically loaded without failing is related to whieh of the following propertiesof a metal?a. hardnessb. toughnessc. tensile strengthd. fatigue strengthe. ductility

F34 In GMAW, the type of metal transfer requiring a special power source is:a. sprayb. globularc. pul sed arcd. short circuitinge. open are

F35 Which of the following is truly a yolumetric test method?a. RTb. UTc. VTd. MTe. PT

F36 Use of preheat will result in:a. a faster cooling rate and wider heat-affected zoneb. a faster cooling rate and narrower heat-affeeted zonee. a slower cooling rate and wider heat-affected zoned. a slower cooling rate and narrower heat-affected zonee. none of the aboye

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F37 Which of the following methods is most Iikely to use a transducer 10 scan for tlaws?a. RTb. MTc. UTd. PTe. VT

F38 For plain carbon steels, how are hardness and tensile strength related?a. increase hardness; decrease tensile strengthb. increase hardness; increase tensile strengthc. decrease hardness; increase tensile strengthd. hardness and tensile strength can both be increased by temperinge. hardness and strength are not related

F39 In GMAW, the welding variable controlled by the wire feed speed is:a. arc lengthb. voltagec. currentd. stickoute. travel speed

F40 The welding variables used to calculate heat input are:a. voltage and currentb. current and travel speedc. voltage, current, and travel speedd. travel speed, preheat temperature, and voltagee. voltage, current, and preheat temperature

F41 As the temperature of the base metal is decreased:a. impact strength decreasesb. tensile strength increasesc. ductility decreasesd. hardness increasese. all of the aboye

F42 During RT, which of the following provides the best protection from radiation for a giventhickness?a. lead shieldingb. steel shieldingc. concrete shieldingd. copper shieldinge. wood shielding

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Welding Inspeclion TechnologyFundamenlals Examination

F43 A weld inspection plan should be developed:a. befare welding beginsb. during weldingc. after welding is completedd. befare shipping the worke. only when there is a problem

F44 If the weld symbol straddles lhe reference line, it means:a. weld both sidesb. weld arrow side firstc. weld olher side firstd. weld has no side significancee. the symbol was drawn incorrectly

F45 An E7ül8 SMAW electrode exhibits which of the following characteristics?a. low hydrogen; use on AC only; iron powderb. low hydrogen; use on AC and DCENc. low hydrogen; AC and DCEP; iron powderd. rutile; DCEPe. rutile; DCEP; iron powder

F46 Piezoelectricity is a material property used by which NDE method?a. UTb. ETc. RTd. MTe. PT

F47 A lhermal treatment lhat follows quenching and restares sorne ofthe metal's ductility is referredto as:a. stress reliefb. temperingc. hardeningd. normalizinge. postheat

F48 Which of these methods is most often used to eliminate the high residual stress created bywelding?a. prebendingb. shot blastingc. quenching rapidly after weldingd. postweld heat treatinge. preheating

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F49 The physical principie that permits the migration of liquid penetran! into very fine surfacediscontinuities is:a. magnetic permeabilityb. optical fluorescencec. capilIary actiond. emulsificatione. so!ubility

F50 The process whereby a large gap is filIed with braze material without the help of capilIary actionIS:

a. torch brazingb. arc brazingc. braze weldingd. dip brazinge. flow brazing

F51 Which of the folIowing contains ferrous base metal specifications?a. AWS Dl.2b. ASME Section n, Part Cc. AWS A5.!d. ASME Section Ve. ASME Section 11, Part A

F52 Which of the folIowing is considered to be the most portable method of magnetization whenconducting a magnetic particle test?a. ACcoilb. ACyokec. DCcoild. DC prode. Head Shot

F53 Advantages of MT inelude:a. the detection of surface flawsb. both AC and DC methodsc. the detection of surface flaws tightly closed by carbon, slag, or contaminantsd. the fact that it is faster than PTe. alI of the aboye

F54 In general, an increase in the carbon equivalent of a carbon steel wilI result in an increase in its:a. ductilityb. hardnessc. defectsd. toughnesse. alI of the above

9

Welding Inspeclion TechnologyFundamentals Examination

F55 A welding process commonly used to join light gage stainless steel tubing for critical applications is:a. SMAWb. GMAWc. GTAWd. üFWe. FCAW

F56 Hydrogen in the molten weld metal can cause:a. undercut and overlapb. cracking and porosityc. incomplete penetration and incomplete fusiond. porosity and slag inclusionse. hydrogen will diffuse during welding and will not cause problems

F57 Which of the following results from improper termination of the SMAW electrode and shrinkingof the molten weld pool during welding?a. porosityb. slag inclusionsc. delayed crackingd. crater crackinge. incomplete fusion

F58 Entrapped slag can result when using aH of lhe following except:a. SMAWb. SAWc. FCAWd. ESWe. GMAW

F59 The material property lhat best describes its ability to withstand a static load is:a. hardnessb. toughnessc. tensile strengthd. fatigue strengthe. torsional strength

F60 The presence of paint on the surface of a part wiH most greatly affeet the results of which NDEmethod?a. PTand MTb. RTand UTc. MTand ETd. UTandETe. ETand VT

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Welding InspeClion TechnologyFundamenlals Examinalion

F61 If no information appears to the left of a groove weld symbol, this means:

a. no weld is required on lhat sideb. the weld is to be complete joint penetrationc. the weld is to be continuous for lhe entire length of the jointd. beveling is not requirede. weld size is to be determined by the welder

F62 Which of lhe following is nol easily detected using RT lhat is perpendicular to the weld centerline?a. throat crack

b. porosityc. side wall incomplete fusion at a bevel angle of 35°d. crater crack

e. incomplete joinl penelration

F63 Dwell time is a term associated with which NDE method?a. MTb. PTc. RTd. ET

e. UT

F64 The material property expressed in lerms of an endurance limit is:a. fatigue strengthb. toughnessc. tensile strenglhd. ductilitye. hardness

F65 Fracture toughness results will often be expressed in terms of:a. breaking energyb. tensile strenglhc. percent elongationd. endurance ¡imit

e. reduction of area

F66 Shielding of the molten pool in üFW is accomplished by:a. a granular fluxb. a chemical reactionc. an inert gasd. a vacuum chambere. a flux paste

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F73 Which of the following is considered lo be parl of lhe welding inspeclor's responsibility lo thepublic?a. undertaking only those assignmenls for which the inspector is qualifiedb. making public statemenls as to the qua lity of a weldmentc. signing for all inspections on lhe jobd. reporting all disconlinuiliese. verify conformance based on pasl experience

F74 Which of the following processes is performed primarily in the flat and horizontal positions?a. SAWb. OAWc. GTAWd. GMAW-Se. SW

F75 A groove weld symbol with no information appearing to lhe right means:a. the weld is to be complele joint penelrationb. no weld is required on that sidec. the weld is to be continuous for lhe enlire joint lengthd. no weldjoint preparation is requirede. weld length can be determined by lhe welder

F76 The welding process thal requires a tubular eJeclrode is:a. SMAWb. GMAWc. FCAWd. SAWe. ESW

F77 The properly relaling lo a metal's resistance lo indentation is:a. tensile strengthb. ductililyc. hardnessd. toughnesse. faligue strength

F78 LT is lhe abbreviation for:a. leak testingb. liquid penetrant testingc. liquid test inspectiond. lilhium testinge. lender test method

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F79 Filler metal specifications are found in which of the following documents?a. AWS AS.I through AS.3Xb. ASME Section 11, Part Ac. AWS A3.0

d. AWS A2.4e. AWS 01.1 Clause 2

F80 The flux covering on an SMAW electrode provides which of the following?

a. gas shielding for the molten poolb. arc stabil ization

c. alloyingd. deoxidation

e. all of the above

F81 When a weld joint preparation is found to be defective, the inspector should:a. allow welding to proceed if he feels that the welder can produce a satisfactory weld

b. instruct the welder in how to overcorne the problemc. report the deficiency to the proper supervisory personneld. require that the parts be disassembled and properly assemblede. none of the above

F82 The orientation of the probing energy source with respect to that of a flaw is considered to be asignificant variable for which NDE method?a. RTb. UTc. ETd. MTe. all of the aboye

F83 Information that appears to the left of the weld symbol refers to:a. the weld lengthb. the weld sizec. the electrode size

d. the number of passes requirede. none of the aboye

F84 Which process uses a granular flux that can be manually added to the weld pool?a. SMAWb. GTAWc. ESW

d. SWe. FCAW

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F8S Of those microstructural constituents listed below, the hardest is:a. martensiteb. ferritec. bainited. austenitee. pearlite

F86 In radiography, the image on the film of a groove weld with a crack extending from the face tothe rool:a. appears as a well-defined, low density, lightly shaded, sharp lineb. appears as a well-defined, high density, darkly shaded, sharp linec. appears as a row of low density light spots or dotsd. appears as a row of high density dark spots or dotse. appears as a white line

F87 A material's ductility is commonly expressed in terms of:a. percent elongation and reduction of areab. width and thicknessc. tensile strength and yield strengthd. toughnesse. fatigue

F88 Who is responsible for verifying welding procedures have been properly qualified?a. independent test labb. contractorc. welding inspectord. architecte. engineer

F89 What MT technique could be used for lhe discovery of longitudinal flaws on a pipe using astationary MT machine or bench unit?a. coil shotb. circular magnetizationc. longitudinal magnetizationd. parallel magnetisme. perpendicular magnetization

F90 Which code gives prequalified status to certain weld joint configurations?a. APIII04b. AWSDI.Ic. AWS 017.1d. ANSI B3 1.1e. AWS B2.1

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F91 Information that appears to the right of the weld symbol refers to the:a. process to be usedb. type of electrode to be usedc. length of weld requiredd. size of weld requirede. required joint configuration

F92 When a clerical mistake is made while completing an inspection report, the inspector should:a. erase the error and fill in the correct informationb. cross out the error and supply the proper informationc. line out the error with a single line, supply the proper information, and initial and date the

occurrence in inkd. attach a note to the report explaining the reason for the changee. erase the error or use white out, initial, and date the occurrence in black ink

F93 The rapid quenching of a high carbon steel from the austenitizing range will result In theformation of:a. pearliteb. martensitec. cementited. ferritee. austenite

F94 When an austenitized carbon steel is cooled to room temperature, an ¡ncrease in the cooling ratewill result in:a. an increase in hardness and a decrease in ductilityb. an increase in tensile strength and a decrease in hardnessc. a decrease in tensile strength and an increase in hardnessd. an increase in ductility and a decrease in hardnesse. a decrease in hardness and an increase in ductility

F95 The heat treatment in which a carbon steel's temperature is raised to the austenitizing range, heldfor a prescribed time and then allowed to cool to room temperature while remaining in thefumace is referred to as:a. stress relievingb. annealingc. normalizingd. temperinge. austenitizing

F96 In which direction does a rolled plate of carbon steel usually exhibit its least amount of ductility?a. parallel to the rolling directionb. transverse to the rolling directionc. in the through thickness directiond. in the direction of weldinge. rolling direction has no significance regarding ductility

16


F97 When a weld has been rejected by a gualified NDE technician, the welding inspector should:a. review the test results and maintain the test recordb. reinspect to verify the defectc. accept the weld if its visual appearance is in compliance with the applicable code or

specificationd. regllire another inspection by a third partye. accept the weld since it is in a low stress region

F98 lf egual thicknesses of steel, cast iron, aluminum, lead, and copper are radiographed using thesame exposure conditions, which material will result in the darkest radiograph?a. leadb. steelc. aluminumd. coppere. cast iron

F99 The welding process that uses a nonconsumable electrode is:a. GMAWb. SAWc. GTAWd. FCAWe. SMAW

F100 The heat treatment in which the metal's temperature is raised to the austenitizing range, held fora prescribed time, and then allowed to cool to room temperature in still air is referred to as:a. austenitizingb. normalizingc. annealingd. gllenchinge. tempering

F101 In a guided bend test, the bend radius is:a. always 5 inb. as specified in the appropriate code or specificationc. 0.5 ind. 0.65 ine. as stated on the MTR

F102 An E71 T-I electrode designation is for which welding process?a. PAWb. FCAWc. SMAWd. GMAWe. SAW

17

:'


F103 A break in the arrow line of a welding symbol has what significance?a. Welding must first be done on the arrow sideb. Welding must first be done on the other sidec. Welding must be done alternately on both the arrow and the other sidesd. The broken arrow line segment points to that member which receives preparatione. an intermittent weld is required

F104 It is discovered that a GMAW mild steel weld was produced with a shielding gas containingexcess moisture. To determine the extent of subsurface porosity that resulted, which NDEmethod would be most effective?a. MTb. RTc. VTd. PTe. ET

F10S Which welding process utilizes a vertical joint orientation with welding occurring in the tlat position?a. ESWb. SAWc. SMAWd. FCAWe. OFW

F10S The heat treatment for carbon steels in which the metal's temperature is raised to just below thelower transformation temperature and held for a prescribed time before allowing it to cool at acontrolled rate is referred to as:a. temperingb. austenitizingc. stress relievingd. normalizinge. preheating

F107 The position on a metal's stress-strain curve referring to its change in behavior from elastic toplastic is the:a. yield pointb. modulus of elasticityc. endurance lim itd. transformation temperaturee. Young's Modulus

F10S Low-hydrogen electrodes can be properly identified by which digit of a ciassification number?a. first digitb. second digitc. first and second togetherd. second to last digite. last digit

18


F109 AH welding symbol information referring to the arrow side of the joint is found:a. in the tailb. aboye the reference linec. below the reference lined. in a notee. to the left of the weld symbol

F110 The marking of a rejectable weld should:a. be clear and understandable to aH involvedb. be made with a steel impression stampc. note the proper repair procedured. always be in rede. always inelude the welder's identification

F111 MT can be used effectively to inspect which of the following metals?a. welds on A 36 steelb. steel welds on stainless steel platec. welds on aluminumd. welds on aH aHoy materialse. materials properly qualified for use with E3üS electrodes

F112 Of the welding processes listed below, the one most commonly having the highest depositionrate is:a. OAWb. GMAW-Sc. SAWd. SMAWe. GMAW

F113 The use of preheat on a medium carbon steel weld test plate will perform aH of the foHowingexcept:a. reduce distortionb. reduce the possibility of hydrogen crackingc. result in the formation of martensited. produce a wide heat-affected zonee. diffuse hydrogen

F114 The tensile test can be used to provide values for which of the foHowing?a. yield pointb. ultimate tensile strengthc. modulus of elasticityd. elastic limite. aH of the above

19


F115 Which of the following is not an acceptable method for control of raw materials?a. color codingb. alphanumeric codingc. first in, first outd. location segregatione. bar coding

F116 In what document are the duties and responsibilities of a CWI described?:a. AWSDI.Ib. AWS A3.0c. ANSI Z49.1d. AWSQC-Ie. AWSQC-7

F117 AII welding symbols require which of the following basic elements in their construction?a. reference line, arrow, and tailb. reference line and arrowc. reference line, arrow, and weld symbold. reference line, arrow, weld symbol, dimensions, and supplementary datae. reference line only

F118 The size of the weld represented in Figure 1:a. is not importantb. cannot be determined directly from the symbolc. can be determined from the symbold. is not specified therefore may be determined by the

weldere. must be found in the WPS

F119 Welding symbol information provided in Figure 1 requires:a. field weldingb. weld-all-aroundc. a fillet weldd. the use of shielded metal arc weldinge. all of the aboye

Figure 1

F120 A shielded metal arc weld was produced in which !he welder failed to properly c1ean betweenpasses in a multipass weld. Which nondestructive test would best reveal the f1aws that may bepresent in !he completed weld?a. RTb. VTc. MTd. PTe. ET

20


F121 SMAW is typically used in which type of application?a. semiautomaticb. machinec. manuald. automatice. mechanical

F122 What position is depicted in Figure 2? RESTRICTION RING

a. 60b. 50c. 6Fd. 6GR 45° ± So

e. 50R

F123 Using the appropriate conversion factor providedin lhe chart on page 40, determine the approximate /diameter in inches for an electrode that measures Figure 21.2mm.a. 0.047 inb. 4.7 inc. 0.0047 ind. 0.47 ine. 47.2 in

F124 Underbead cracking is primarily caused by:a. a source of hydrogenb. restraintc. excessive preheatd. fatiguee. excessive loading

F125 Which of the following is a correct statement about brazing?a. the base metal is not meltedb. the filler metal melts at a temperature below SOO°Fc. it must be done in an inert gas atmosphered. in order to achieve capillary action large root opening is requirede. inert gases may be substituted for oxygen

F126 Which of lhe following welding processes commonly use a constant current power source?a. OMAW and FCAWb. SMAW and OTAWc. OTAWandOMAWd. FCAW and SMAWe. SAW and SMAW

21


F127 The firsl operalion required by lhe symbol in Figure 3 is:a. ullrasonic inspeclion of lhe base metalb. visual inspeclion of joinl preparationc. welding a V-groove from lhe olher-side of lhe joinld. welding a backing weld from lhe arrow-side of lhe joinle. backgouging and back welding from the arrow-side of lhe

joint

F128 For Figure 3, ultrasonic inspeclion is lo be performed:a. on the back weld onlyb. on the entire length of the other side weldc. on 10% of lhe weld lengthd. from the arrow sidee. on lhe single V groove, from lhe arrow side

UT

Figure 3

F129 Which of the following discontinuities are associaled wilh shrinkage stresses in lhe throughthickness direclion of thick plate?a. craler cracksb. lamellar learsc. toe cracksd. root crackse. none of lhe above

F130 Which of the welding lechniques below describes a welding process in which lhe filler melalfeeding is machine operaled while lhe joint lravel speed and guidance are lhe responsibilily ofthe welder?a. semiaulomalicb. manualc. machined. automatice. mechanized

F131 The welding symbol shown in Figure 4 depicts:a. a backing weld olher-side followed by a V-groove weld arrow-

sideb. a V-groove weld arrow-side followed by a back weld other-sidec. a V-groove weld arrow-side with melt-throughd. a bevel groove weld made one-half the way around lhe diameter

of a pipee. a V-groove weld arrow-side with the root finished to a convex conlOur

22

-

Figure 4


F132 Which of the following symbols correctly describes the joint configuration shown in Figure 57

7/16 (1/4) I , /a.7/16 (114) 7/16

, / 1/4, / 11TI

1/4 (7/16), /, fb. 7/16 / ,

1/41/4 (7/16) 1 / ,

1

Figure 5c.

d. 1/4 (7/16)1/4 (7/16)

e. none of the above

F133 The width of the cut produced during a cutting process is referred to as:a. root openingb. kerfc. beveld. bevel anglee. chamfer

F134 For the 2G position in pipe welding:a. the axis of the pipe is vertical and the plane of the weld is horizontalb. the axis of!he pipe is horizontal and the plane of!he weld is verticalc. the pipe is not fixedd. the axis of the pipe and the plane of the weld are at 45° angles with the vertical planee. the axis of the pipe is horizontal and the pipe is rotated

F135 During operation, the heat for electroslag welding is provided by:a. the arcb. the electrical resistance heating of the molten slagc. the consumable guide tube meltingd. current passing through the base metale. current passing through the filler wire

23


F136 Using the appropriate conversion factor provided in the chart on page 40, determine the approximate cubic feet per hour (cfh) for a flow rate of 22 Iiters per minute.a. 466 cfhb. 46.6 cfhc. 10.38 cfhd. 103.8 cfhe. 4.66 cfh

F137 It is suspected that a GMAW weld was produced in an area where there was an excessive draft.Which nondestructive test would best reveal the internal discontinuities which may haveresulted?a. PTb. MTc. RTd. VTe. none of the above

F138 The size of the arrOw side weld in Figure 6 is:u. 1/4 inb. 5116 inc. 1 ind. 2 ine. 1 in deposited every 6 in

F139 The length of the other side weld in Figure 6 is:u. 1 inb. 6 inc. 2 ind. 4 ine. continuous down the length of the joint

F140 The pitch of the other side weld in Figure 6 is:a. 1/4 inb. 4 inc. 5116 ind. 1 ine. 6 in

1/4 2-4

5/16 1-1;

Figure 6

F141 If a contour symbol is used but the finishing method is not specified on the welding symbol:a. it is the inspector' s choiceb. it is the fabricutor's choicec. the desired contour must be as-weldedd. it should be found in the code specifiede. it is the welder' s choice

24


F142 In order to learn the exact location of a subsurface fiaw in three directions. the best NDE methodwould be:a. RTb. MTc. PTd. UTe. VT

F143 The surface of a member included in the groove of a weldment best describes:a. root openingb. groove anglec. weld interfaced. groove facee. none of the above

F144 Crater cracks can be the result of:a. poor welding techniqueb. abrupt termination of weldingc. shrinkage of lhe molten poold. underfill of the cratere. all of the above

F145 Figure 7 depicts which weldingprocess?a. SAWb. SMAWc. PAWd. GMAWe. FCAW

SLAG

ElECTRODE

MOlTENFLUX

--- DIRECTION OF TRAVEl •

Figure 7

F146 The boundaries indicated by "A" in Figure 8 are:a. fusion lineb. depth of fusionc. weld interfaced. fusion facee. none of the aboye

B

Figure 8

25


c. "e"d. "D"

F148 The weld interface in Figure 8 is indicated by:a. HA"

F147 The dimension "O" in Figure 8 is referred to as:a. fusion faceb. fusion zonec. depth of fusiond. weld interfacee. fusion line

Figure 8"B"b.

e. none of the aboye

F149 Using the appropriate conversion factor provided in the chart on page 40, determine the approximate degrees Celsius for a preheat temperature of 225°F.a. 225°Cb. 107°Cc. 437°Cd. 10.7°Ce. 1.07°C

F150 Which of the following welds is not considered applicable for a butt joint?a. V-grooveb. plugc. edge-tlanged. U-groovee. J-groove

F151 The dimension "A" in Figure 9 refers to:a. root penetrationb. weld penetrationc. depth of fusiond. joint penetratione. side wall penetration

F152 The dimension "c" in Figure 9 identifies:a. joint penetration and weld sizeb. weld size and root penetrationc. depth of fusiond. complete joint penetratione. incomplete joint penetration

B

o

Figure 9

e

26


F153 Which of the following is not a type of weld joint?a. lapb. T-c. filletd. butte. edge

F154 When using SMAW, wet electrodes will most likely cause:a. undercutb. overlapc. underfilld. porositye. all of the aboye

F155 Which of the following is considered to be an acceptable way to provide backing for a V- grooveweld in a carbon steel butt joint?a. copper backing barb. ceramic backingc. flux backingd. backing welde. all of the aboye

F156 A welder deposits an average of 12 pounds of weld metal per hour. Using the appropriate conversion factor provided in the chart on page 40, determine the approximate kilograms of weldmetal that will be deposited in 6 hours of continuous welding.a. 5 kgb. 33 kgc. 6 kgd. 26 kge. 37 kg

F157 A single-wire, submerged arc welding machine is operating at 32 volts, 600 amps, and is traveling at 8 inches per minute. Using the formula provided below, what is the heat input for thissituation?

Heat input = J/in V x A x 60J/i n = =:----'.,..e;..:....:...;..;",.::.::,--Travel Speed (ipm)

a. 2400 J/inb. I 152000 J/inc. 1.44 x 105 J/ind. 110000 J/ine. 14400 J/in

27


F158 The pipe welding test position in which the axis of the pipe is horizontal and the pipe is rotatedso that welding takes place at or near lhe top is designated as:a. 2Gb. 2Fc. IGd. 3Ge. 6GR

F159 The most efficient NDE method for discovery of undercut on the face of a weld is:a. VTb. RTc. UTd. MTe. PT

F160 The design strength of a fillet weld is always based on the throat dimension because:a. it has a columnar microstructure, which is more prone to crackingb. il is the shortest failure path through the weldc. il is the location of most defectsd. the design calculations cannot be checkede. il is a theory of failure that cannot be supported by actual laboratory testing

F161 Arc strikes are discontinuities most commonly associated with:a. ESWb. SAWc. SMAWd. OAWe. SW

F162 Double-groove welds in butt joints always require:a. backgougingb. special welding processesc. high deposition rate processesd. weld to be deposited from both sides of the jointe. a spacer to hold critical root openings

F163 What welding process is depicted inFigure la?a. FCAWb. GMAWc. SMAWd. SAWe. ESW

28

ELECTRODE COVERING------..

COREWIRE


F164 Light-colored areas within the weld zone in a radiograph could represent:a. porosity and trapped sIagb. tungsten incIusions and meIt-throughc. melt-through and trapped slagd. porosity and tungsten inclusionse. underfill and excessive reinforcement

F165 A single V-groove weld requires:a. special welding processesb. backgougingc. a backing bard. no root openinge. CJP unless otherwise specified

F166 The substance used in UT to aid In the transmission of sound from the search unit to theworkpiece and back is called:a. solventb. attenuationc. couplantd. cablee. transducer

F167 Using the appropriate conversion factor from the chart on page 40, determine the approximatekilogram weight of a 30 pound roll of weIding wire.a. 1.36 kgb. 66 kgc. 136 kgd. 66.15 kge. 13.6 kg

F168 The junction of the weld face with the exterior surface of the base metal is referred to as the:a. faceb. rootc. legd. toee. edge

F169 InternaI plate laminations are best revealed using:a. UTb. RTc. MTd. PTe. ET

29


F170 Porosity in GMAW can be caused by:a. draftsb. contaminationc. too little shielding gas f10wd. too much shielding gas f10we. all of the aboye

F171 The oyerhead fillet position is designated as:a. 5Fb. 4Fc. 3Fd. 2Fe. IF

F172 The radiograph in Figure II shows:a. crackb. incomplete fusionc. incomplete joint penetrationd. slag inclusionse. none of the aboye

Figure 11

F173 The welding process depicted in Figure12 is:a. GMAWb. SAWc. SMAWd. GTAWe. PAW

•DIRECTIDN DF WELDING

Figure 12

30


F174 The radiograph in Figure 13 shows:a. slag inclusions due to improper fit upb. tungsten inclusions due to poor tungsten

grindingc. porosity due to inadequate shieldingd. longitudinal crack due to stresse. lack of penetration due to poor starts and

stops

F175 Which of the following is an example of anelectrode classification number for GTAW?a. EWTh-2b. AS.Ic. AS.9d. E7018e. ER70S-2

Figure 13

F176 In a groove-weld cross section, the 'Iine' separating weld metal from base metal is called:a. the fusion faceb. the depth of fusionc. the depth of penetrationd. the weld interfacee. none of the aboye

F177 In the radiograph in Figure 14, the arrows poin! to:a. transverse cracksb. crater cracksc. longitudinal cracksd. underbead crackse. toe cracks

F178 In pipe groove welding, the 4So fixed position IS

designated as:a. IGb. 2Gc. 2Fd. SGe. 6G

Figure 14

F179 Using the appropriate conversion factor provided in the chart on page 40 determine the approximate feed speed in inches per minute for a wire fed at a speed of 120 mm/s.a. 28.3 ipmb. 283 ipmc. 2834 ipmd. S.076 ipme. SO.76 ipm

31


F180 The defect noted in the radiograph in Figure 15 is:a. incomplete penetrationb. a crackc. incomplete fusiond. porositye. slag inclusions

F181 The "A" dimension in Figure 16 is referred loas:a. actual weld throatb. weld sizec. weld legd. theoretical weld throate. effective weld throat

F182 "F" in Figure 16 points to:a. the root penetrationb. the weld penetrationc. the weld rootd. the beginning of the joint roote. none of the aboye

F183 The dimension "e" in Figure 16 shows:a. the theoretical throatb. the actual throatc. the effective throatd. weld lege. convexity

F184 The dimension "O" in Figure 16 is caBed:a. the theoretical throat and the effective Ihroatb. the effective throat and the actual throatc. the actual throat and the theoretical throatd. weld sizee. convexity

F185 The dimension "E" in Figure 16 refers to:a. the actual throatb. the effective throatc. convexityd. leg and weld sizee. concavity

32

Figure 15

e

Figure 16


F186 One common cause of centerline weld cracks is:a. the use of preheatb. a highly restrained weld jointc. using the wrong polarityd. stress relief heattreatmente. the presence of incomplete sidewall fusion

F187 Using the appropriate conversion factor from the chart on page 40, determine the approximatepounds per square in (psi) for a yield strength of 198 MPa.a. 2.871 x 103 psib. 2.871 x 104 psic. 4136 psid. 41.36 psie. 2871 psi

F188 Which NDE method will best reveal subsurface porosity?a. RTb. PTc. MTd. UTe. none of the aboye

=189 In a PT examination scallered round indications on the surface of a weld could be indicative of:a. fatigue cracksb. porosityc. overlapd. grinding cracksc. undcrcut

F190 Using the conversion factor provided in the chart on page 40, determine the approximate MPafor a tensile strength of 65 000 psi.a. 448000b. 4.48 x 108

c. 448d. 9425000e. 9.425 x 106

F191 An MT indication of a subsurface discontinuity I in below the surface will appear how as compared to a surface discontinuity?a. intermillentb. sharperc. less distinctd. MT cannot detect a subsurface flaw 1 in below the surfacee. only the central conductor method can be used to detect flaws in I in material

33


F192 Which of the following conditions can cause slag inclusions in a weld?a. insufficient groove angle in an SMAW single V-groove weldb. careful interpass cleaning of subsequent layer and beads of FeAWc. insufficient preheat of test plated. insufficient shielding gas flow in GTAWe. improper fit up of GMAW test plates

F193 What is meant by the term essential variable?a. Data on a WPS that if changed beyond code limits during production wilI render a WPS

disqualified.b. Data on an inspection report that if ehanged render the report disqualified.c. Data on an MTR that is essential to the chemistry of the material.d. the reeommended amperage and voltage for welding as published by the manufacturer.e. describes what should be included in a WPS.

e

Figure 17

F194 The dimension "B" in Figure 17 is:A

a. the weld throat E

b. the weld sizec. point of tangencyd. groove weld sizee. filIet weld profile

F195 The dimension "A" in Figure 17 is the:a. convexityb. concavityc. face reinforcementd. weld sizee. overlap

F196 The dimension "E" in Figure 17 is:a. the actual throatb. the effective throatc. the theoretical throatd. weld sizee. convexity

F197 The dimension "D" in Figure 17 is:a. the actual throatb. the effective throatc. the theoretical throatd. weld sizee. weld leg

34


F198 Where should the preheat temperature be measured?a. in the weld grooveb. 12 in from the weld groovec. where the arc will be initiatedd. 2 in-3 in from point of weldinge. preheat temperature need not be measured

F199 A discontinuity is:a. always rejectableb. never rejectable, but its condition should be noted in the inspection reportc. always a defectd. an indication that renders a part unusablee. an interruption in the uniformity of a weldment

F200 What weld discontinuity is shown in the radiographin Figure 18?a. crackb. incomplete joint penetrationc. porosityd. burn throughe. tungsten inclusions

F201 An oxygen regulator is set for 40 psi. Using theappropriate conversion factor from the chart on page40, determine the pressure in kPa.a. 2758b. 27580c. 2.758d. 27.58e. 275.8

Figure 18

F202 Which of the following discontinuities can be caused by poor welding technique?a. incomplete fusionb. porosityc. undercutd. overlape. all of the above

F203 If a welder is continually turning out rejectable work, the welding inspector should:a. inspect his work more criticallyb. ask that the welder be terminatedc. require requalificationd. instruct the welder in proper techniquese. ask !hat the welder use another process

35


F204 How does a welder become certified?

a. certification can only be obtained by taking a weld test given by a CWIb. by graduating from a welding school

c. by having documented proof of 5 years in welding industry

d. by documenting successful completion of a weld test according to the requirements of anapplicable standard

e. certification can only be obtained by taking a weld test at an approved test center

F20S Which discontinuity occurs in the heat-affected zone and can result from excess moisture in theweld zone?

a. throat crack

b. crater crackc. underbead crack

d. porositye. centerl ine crack

F20S Which of the following measurements are taken from a tensile specimen to determine area?

a. mass and volumeb. length and thicknessc. width and length

d. width and thicknesse. load and pressure

F207 When establishing a PQR?a. the type and number of tests required is determined by the applicable standard

b. a face and root bend will qualify all platesc. testing requirements are determined by the contractor and approved by the :nspectord. destructive testing is required only if a prohlem is suspectede. a weld test plate does not have to be mechanically tested to establish a PQR

F20a Which of the following discontinuities is not associated with GTAW?a. lack of fusionb. slag inclusionsc. tungsten inclusions

d. porositye. undercut

F209 Using the appropriate conversion factor from the chart on page 40, convert a travel speed of21 ipm to mm/s.a. 88.9b. 8.9c. 0.88d. 0.088e. 49.61

36


F210 Using the appropriate conversion factor from the chart on page 40, calculate the ultimate tensilestrength in MPa of a tensile specimen having a cross-sectional area of OJOO sq in and whichbroke at a tensile load of 24600 lbs.

Load (lbs)Area of specimen (sq in)

a. 565 Pab. 565 MPac. 5.65 Pad. 565 kPae. 5650 kPa

= Tensile strength (psi)

F211 Which of the following discontinuities are not found with GMAW?a. incomplete fusionb. porosityc. tungsten inclusionsd. incomplete penetratione. cracks

F212 The CAWI:a. is solely responsible for determination of a weldment's conformance to acce[Jtable standardsb. inspects weldments only under the direction of a CWI or SCWIc. cannot inspect critical weldmentsd. performs all inspections the same as a CWIe. all of the aboye

F213 The performance of which of the foIlowing test methods is least affected by high part temperatures?a. ETb. RTc. PTd. UTe. none of the aboye

F214 Base metal thickness can be determined using which of the following?a. MTb. UTc. ETd. a and c aboyee. b and c aboye

F215 The mating surface between two overlapping base metal s to be joined is called:a. weld interfaceb. faying surfacec. weld edged. groove facee. none of the aboye

37


F216 A deyeloper is used as one of the steps in which NDE method?a. UTb. MTc. PTd. a and b aboyee. b and c aboye

F217 ET is the abbreYiation for which NDE method?a. eddy current testingb. enyironmental testingc. emissiye testingd. a and b aboyee. b and c aboye

F218 To be mosl effectiye, Yisual inspection must be conducted:a. before weldingb. during weldingc. after weldingd. al! of the aboyee. b and c aboye

F219 Which of the conditions below can cause porosity in a weld?a. welder techniqueb. damp electrodesc. oily base metald. rainy weathere. al! of the aboye

F220 Which of the fol!owing are common causes of undercut when using SMAW?a. weld current too highb. improper electrode manipulationc. welding electrode loo larged. improper electrode anglee. al! of the aboye

38


wlr-Useful Formulae

Area 01 Square or Rectangle

Area = length x width

Area or Circle

or: Area = width x thickness

Area = n x radius2

Percent Elongation

or: Ardiameter2

ea=nx 4 or: Area = 0.7854 x diameter2

% Elongation =Final Gage Length - Original Gage Length

Original Gage Lengthx 100

Percenl Reduction 01 Area

% Reduction of Area =

Tensile Strength

General

Original Area - Final AreaOriginal Area

x 100

UTS = P max.Area

UTS for full section pipe =

where: P max. = load to break specimen

Area = specimen's original cross-sectional area

Pmax.

where: J = Joules (energy)V = welding voltageA = welding amperageipm = inches per minute

Yield Strength

YS = Load at specified offsetOriginal cross-sectionaI area

Welding Heat Input

J/in = V x A x 60Travel Speed (ipm)

Carbon Equivalenl

39


Welding Usage Conversion Chart-U.S. Customary and SI

Property' To Convert From: To: Mulliply By:

area dimensions in2 mm2 6.452 x 102

mm2 in2 1.550 x 10-3

current density A/in2 A/mm2 1.550 x 10-3

Almm2 A/in2 6.452 x 102

deposition rate Ibfhr kg/hr 0.454kg/hr Ib/hr 2.205

now rate ft3fh I/min 4.719xlO-1

I/min ft3/h 2.119

heat input J/in J/m 39.37J/m J/in 2.54 x 10-2

linear measure In mm 25.4mm in 3.937 x 10-2

ft mm 3.048 x 102

mm ft 3.281 x 10-3

mass lb kg 0.454kg lb 2.205

pressure psi kPa 6.895pSI MPa 6.895 x 10-3

kPa psi 0.145MPa psi 1.450 x 102

bar pSI 14.50pSI bar 6.9 x 10-2

temperature °F oC (OF - 32)/ 1.8oC °F (OC x 1.8) + 32

tensile strength pSI MPa 6.895 x 10-3

MPa psi 1.450 x 102

travel speed in/min mm/s 4.233 x 10-1

mlO/S in/min 2.362

vacuum Pa torr 7.501 x 10-3

wire feed speed in/min mlO/S 0.423mlO/S in/min 2.362

40


ANSWER KEY

FI e F45 e F89 b FI33 b FI77 aF2 a F46 a F90 b FI34 a FI78 eF3 e F47 b F91 e FI35 b FI79 b

F4 a F48 d F92 e FI36 b FI80 d

F5 b F49 e F93 b FI37 e FI81 b

F6 a F50 e F94 a F!38 b FI82 d

F7 e F51 e F95 b FI39 e FI83 aF8 b F52 b F96 e FI40 b FI84 bF9 e F53 e F97 a F!41 e FI85 eFIO e F54 b F98 e F!42 d F186 b

Fll e F55 e F99 e FI43 d F187 bFI2 a F56 b FIOO b FI44 e F188 aFI3 e F57 d FIOI b FI45 a FI89 bFI4 b F58 e FI02 b FI46 d FI90 eF15 b F59 e FI03 d FI47 e FI91 d

F16 e F60 a FI04 b FI48 b FI92 aF17 e F6! b FI05 a FI49 b F193 aF18 d F62 e FI06 e FI50 b F194 b

F19 e F63 b FI07 a FI51 e F195 aF20 e F64 a FI08 e FI52 a F196 aF21 b F65 a FI09 e FI53 e F197 b

F22 b F66 b FIlO a FI54 d F198 d

F23 d F67 e FIII a FI55 e FI99 eF24 e F68 e FI12 e FI56 b F200 eF25 e F69 b FI13 e FI57 e F201 eF26 d F70 e FI14 e FI58 e F202 eF27 e F71 b FI15 e FI59 a F203 eF28 e Fn a F116 d F160 b F204 d

F29 d F73 a FI17 b F161 e F205 eF30 b F74 a FI18 b F162 d F206 d

F31 b F75 e F119 e F163 e F207 aF32 a F76 e F120 a F164 b F208 b

F33 d F77 e F121 e F165 e F209 b

F34 e F78 a FI22 d F166 e F210 b

F35 b F79 a FI23 a FI67 e F211 eF36 e F80 e FI24 a FI68 d F212 b

F37 e F81 e FI25 a FI69 a F213 aF38 b F82 e FI26 b FI70 e F214 e

F39 e F83 b FI27 e FI71 b F215 b

F40 e F84 e FI28 b Fin e F216 eF41 e F85 a FI29 b FI73 d F217 aF42 a F86 b FI30 a F174 e F218 d

F43 a F87 a F131 e F175 a F219 e

F44 d F88 e F132 b F176 d F220 e

41

aws_welding inspection tecnology workbook_ed 5

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