TECHNOLOGY

Duties before welding

1. How do we determine what the correct weld preparations(root gap, rootface , included angle )
should be ?
a. By consulting the WPSs
b. The fabrication drawing will give all the information
c. The welder will decide
d. Welders and inspectors will decide
2. Voltage and amperage meters have been removed from MIG/MAG (GMAW) equipment making
calibration invalid ,the equipment should be :
a. Quarantined
b. Only used for tack welds
c. Only used if validated
d. Monitored closely by the welding inspector for amperage and voltage

3. Which of the following information should the welding inspector enter on an electrode vacuum pack
at the point of breaking the vacuum?

a. Welder’s name
b. Weld ID number
c. Air humidity content
d. Time and date of opening

4.Who should have access to the WPQRs?

a. NDT operators
b. Inspectors only
c. Welders only
d. Welding engineer

5. A maximum interpass temperature is generally given to control?

a. High HAZ hardness

b. Low HAZ toughness

c. lack of inter – run fusion

d.Excess levels of penetration

6.Why is it sometimes necessary to preheat the basic material before welding

a. Remove oil and grease

 b. Remove moisture from the inside of the material

c .Prevent the possible risk of cracking

e. Not required if using cellulosic electrodes, as these will provide enough heat

7.Which BS EN standard is used for weldig symbols on drawings ?

a. BS EN 970

b. BS EN 287

c. BS EN 22553

d. BS EN 4515

8.What does the term WPQR mean

a. Weld productivity quality review

b. Weld production quality requirements

c. Welding procedure qualification record

d. Work production quantity review

9.The WPS calls for a root gap to be between 2 and 3mm,the actual measured gap is 4 mm, what course
of action would you take ?

a. Accept it as its only 1 mm

b. Reject it
c. The welder will decide, if it fails it will be his problem
d. The welder insists he can weld the butt joint easily so let him go ahead .

10.Which of the following welds maybe made in an open corner joint?

A .Plug weld
b. Butt weld
c. Fillet weld
d. Any of the above

11.Reference to any inspection hold point during manufacture will be contained within the ?

a. Quality manual
b. QA procedures
c. Quality plan
d. standards
Duties during welding

12. The welders have increased the electrode stickout length of the SAW set,what would be the effect
on the weld

a. No effect
b. The weld width would be narrower
c. Penetration will be increased
d. The deposition rate would be greater
13.Why is the OCV capped at a certain level?

a. Save electricity
b. Reduce the risk of fatality
c. To prevent exploding of the consumable
d. Allow smooth transition into welding voltage range
14.When would you measure the maximum interpass temperature
a. immediately after completion of the each pass
b. immediately prior to commencing the next pass
c. When the welding is finally complete
d. maximum interpass temperature measurement is not an essential requirement
15.The welders have increased the voltage on the SAW set. What would be the effect on the weld
appearance ?

a. No effect
b. The weld width would be narrower
c. Penetration will be increased
d. The weld width would be wider.
16.You notice that a welder is using an unapproved WPS for production tack welding carbon steel,
what action would you take?
a. Have the tacks removed and MPI the weld preparation for cracking
b. Nothing as it is only tack welds and they will probably be removed anyway
c. Nothing as long as the WPS covered the material type, wall thickness and diameter
d. Give him he correct approved one and allow him to continue as long as the welding
consumables
17.You notice that the welders are adjusting the current on the welding set ,is this allowable

a. Never
b. The weldr has he final say on voltage and current
c. Only ifthe current is within the range recorded on the WPS
d. As long as the welder has approved from the welding foreman
18.During root welding, which of the following would be the main cause of burn through?
a. Current too high
b. Root gap too small in accordance with WPS
c. Preheat not used
d. Root face too large
DUTIES AFTER WELDING
19. What information should be recorded as a minimum ,on a completed production weld ?
a. Size and type of electrode used
b. Welding supervisor’s name
c. Welder’s identification, date and weld number
d. Welding inspector’s name
20.You find several unacceptable welds and reject them, the welding supervisor insists they are
acceptable, he signs them off and requests NDT ,w hat action would you take
a. Nothing as he is a welding supervisor and knows a great deal about welding
b. Raise the issue with the QC department supervisor
c. It is not my problem as he has signed them off so I will not be blamed
d. look at the NDT results and if they look reasonable I would accept them.
21.why is it essential to clean the surrounding parent metal adjacent to the weld metal made by MMA
(SMAW) which is to be ultrasonically tested?
a. Sound waves will not travel through paint
b. Remove any rust
c. The spatter will impede the contact of the probe and the parent material surface
d. The spatter will reflect the backwall echo signal and give spurious indications
22.To assess the surfaces of a weld for direct inspection, the distance from the surface to the eye should
be a maximum of.?
a. 200 mm
b.600mm
c.60mm
d.6000mm
23.Who should select the specific welds for NDT to cover the 10% contractual percentage required by
the specification /Code ?
a. Any one can select the welds as its’s a random choice
b. The welder as he knows which welds are likely to produce fewest defects
c. will be referenced in the inspection and test plan
d. Nobody as welding is always carried out to a high standard the use of percentage NDT is of
no real value.
24.Who has the responsibility of ensuring the welder is using the correct polarity during welding

a. Welder and welding I inspector

b. Store man and welder
c. Weling engineer
d. Q/A department
MECHANICAL TESTING
25. In a welding procedure transverse joint tensile test the following observations were made.
The specimen CSA was recorded as 30 mm X 20mmand the maximum load applied was recorded as
200KN .what is the UTS?
a. 33kN/mm2
b. 333N/mm2
c. 3333N/mm2
d. 33N/mm2
26.Charpy impact tests showing a rough torn surface after the completed test would indicate which type
of failure ?
a. Fatigue
b .Ductile
 c .Fatigue to ductile
e. Brittle
27.Which of the following is NOT a quantitative test
a. Root bend
b. Macro hardness
c. Charpy
d. tensile
28.When transverse tensile testi ng a welded joint excess weld metal is often removed .This action is
done to:
a. Allow the test piece to fit accurately into the equipment
b. Reduce stress concentrations to the weld toes
c. Allow strain gauges to be placed over the weld face area
d. Allow weld metal ductility to be measured.
29. In an all weld tensile test, the original specimen gauge length was 50 mm and after the test the
increased guage length was 65 mm. What is the elongation percentage
a. % A is 40
b.% A is 60
c.% A is 30
d. % A is 36
30.In welder qualification testing of 10 mm plates,2 root and 2 face bends were tested .1 root bend
failed what course of action would you follow?
a. Accept them as 75% were acceptable , you are allowed one failure
b. 2 more root bends should be prepared and tested
c. 2 more root and 2 more face bends should be prepared and tested
d. Retest the welder.
31.An STRA test is carried out to determine which of the following ?
a. A quick indication of the weld quality for welder qualification tests
b. The test results can be used to verify that the material has not been adversely mechanically
damaged bythe heat during welding
c. An indication of the material’s elongation properties.
d. An indication of the through thickness ductility (in the Z direction)
32.Charpy impact test show a 50% rough torn surface and a 50% flat crystalline surface after completed
test, this would indicate which type of failure .
a. Fatigue and brittle
b. Ductile and brittle
c. Ductile with gross yielding
d. Fatigue and ductile
33. Which of the following defects are unlikely to be detected by normal radiographic techniques?
a.Intergranular corrosion cracking
b.porosity
c. Slag
d. lack of penetration
Processes
34. In which of the following modes of transfer is inductance usually a variable parameter in solid wire
MAG welding (135).
a. Dip transfer
b. Spray transfer
c. Pulse transfer
 d. Globular transfer
35.A disadvantage of the MIG/MAG(131/135) spray transfer condition isthat it.
a. Cannot be used in the vertical position for steels
b. Cannot be used for aluminum alloys
c. Has a low heat input and is prone to lack of sidewall fusion
d. Is said to have lower deposition rate than dip transfer
36.An advantage of the MMA(111) welding process is that it.
a. Has higher current density than SAW(121)welding
b. Has a very large range of consumables for most welding applications
c. No core wire is lost during the process
d. Requires a lower skill level than other manual forms of welding
37.Which of the following inspection points is most critical in affecting arc conditions during the spray
transfer MAG welding (135) process?
a. All electrical connections and contacts
b. Gas flow rate
c.Inductance settings
d. Electrode coating type
38.Due to the high heating effect in the electrode when TIG welding (141) with AC it is important that a
tungsten electrode used for AC welding is:

a. Ground to a fine vertex angle of <30°before welding

b. Used straight from the packet without any grinding
c. Lightly ground to a slight chamfer (corners only removed )
d. Used without grinding and baked at 300°C an hour before use.
39.When welding vertically up with the MMA process weaving is sometimes restricted to 2.5 X electrode
diameter, this restriction is mainly applied to
a. Reduce the overall width of the weld
b. Limit the heat input into the joint
c. Reduce the number of electrodes used in the joint.
d. reduce the time required to finish the weld
40.An advantage of the SAW process is that
a. It can be used in the vertical down (PG) position
b. Little or no ozone or UV light is produced/emitted
c. it is not affected by arc blow
d. It is not prone to solidification cracking
41.A typical minimum OCV requirements for MMA (111) using either rutile or cellulosic electrode
would be.
a. 40 volts
b. 120 volts
c. 100 volts
d. 50 volts
42.A typical minimum OCV requirements for MMA (111) using basic electrodes would be.
a. 70 volts
b. 40 volts
c. 100 volts
d. 20 volts
NDE
43. A high level of surface cleaning is important prior to Penetrant testing in order to
 a. Reduce the amount of penetrant used
b. Reduce the level of false indication
c. Ensure a good bond for the developer
d. improve the viscosity of the penetrant
44. Which of the following is considered the main restriction of the radiographic method of NDT?
a. The detection of planar defects not oriented parallel o the beam direction
b. The range of material thickens it can be used for
c. Cannot be used
d. for remote site work
e. The range of material types it can be used for
45.For which of the following types of NDT does the term prode relate
a. Ultrasonic testing
b. Radiographic Testing
c. Penetrant testing
d. Magnetic testing
46.A restriction of the MPI method of NDT testing is that it can:
a. Only be used of non ferrous metals
b. not be used on ferritic stainless steels
c. only be used magnetic materials
d. Not be used on materials over 3mm thickness
47.Which of the following would be most unlikely to be found in a butt welded butt joint using the
conventional radiographic method of NDT?
a. Linear elongated slag inclusions in the root (wagon tracks)
b. Burn through
c. Lack of sidewall fusion
d. An elongated gas cavity
48.Which of the following is a disadvantage of the radiographic method of NDT?
a. Access to both sides of the welded joint is required
b. The process cannot be used on large grained metals
c. Gamma ray radiography is not very portable
d. Gamma ray radiography is limited to 25 mm thickness in steels
49. An AC yoke is a device used in which NDT technique?
a.magnetic particle testing
b. penetrant testing
c. radiographic testing
d. ultrasonic testing
50.Which of the following is considered the main restriction of the radiographic method of NDT
a. Orientation of planar defects
b. Range of material thickeness
c. use for remote site work
d. range of material types
51. For ultrasonic testing , which of the following statements is true?
a. it is easy to identify all defects
b. The equipment should be calibrated before use
c. The equipment cannot be automated
d. Sound waves will not travel through copper
weldability
52. in a heavy plate fabrication where S is residual @ 0,3% which may cause problems in the welded
joint, additions of Mn maybe added to prevent
a. Laminations in the plate through thickeness
b. stress corrosion cracks
c. Manganese sulphides (MnS)
d. Solidification cracking
53.Pre heats are used on steel joints of high harden ability mainly to.
a. Slow the cooling rate of the steel
b. Remove surface moisture from the joint
c. reduce the formation of surface oxides
d. increase the diffusion rate of hydrogen into the HAZ
54.Lamellar tears in steel weldments may only be formed when
a. using deep penetration welding process (high current density)
b. high levels of stresses act in the short transverse direction in the steel .
c. martensite has formed in the weld HAZ
d. Low melting point iron sulphide (Fes) has formed in the fusion zone
55.Lamellar tearing is a problem in steels which is always associated with?
a. Sensitisation in the HAZ
b. Low through thickeness ducility
c. Hydrogen levels above 15 ml//100g of weld metal
d. Rapid cooling from above the upper critical
56.Sensitisation is a term applied to the formation of which intermettalic compound at the grain
boundaries in the HAZ of austenitic steels?
a. Chromium carbide
b. Titanium carbide
c. Niobium carbide
d.Molybdenum carbide
57.Which of the following processes is most prone to solidification cracks
a.MMA with basic coated electrodes
b. MMA with rutile coated electrodes
c.TIG
d.SAW
58.The temperature gradient of steels subjected to post heat treatment stress relief cycle mustbe
carefully controled at all the temperatures above 300 ° C in order to
a. Ensure that a minimum of expensive heat energy is used
b. reduce the formation of hard martensitic structure
c. allow the weld to diffuse any hydrogen intothe HAZ
d. Heated to a full transformation to austenite then rapidly cooled.
59.For the structure termed martenstic to form in a C-Mn steel it must first be heated to?
a. Just below its lower critical temperature and rapidly cooled.
b. A maximum temperature of 550°C then rapidly cooled.
c. Above its upper critical temperature and slowly furnace cooled
d. A full transformation to austenite then rapidly coole
60.Which of the following could be used to minimize the occurrence of solidification cracks in steels
welds?
a. increase sulpher levels to a minimum of 0.5%
b. Reduce the dilution into the base metal
c. Increase carbon content in the weld metal
d. reduce the manganese content in the weld metal.