Practical Macro Inspection

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Course notes section reference 25.0
Welding Inspector CSWIP 3.1
 Macro Inspection Examination
Remember in the CSWIP 3.1 Welding Inspectors
examination your are required to answer 12 multiple choice
questions. Candidates are required to sentence the
indications they have identified and should reference the
acceptance levels provided within the folder

• Time allowed 45 minutes

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• Examination Acceptance code
TWI 09
 Macro Inspection Examination
The candidate is issued with two photographs a macro
sample with arrows pointing to indications candidates are
required to:
• Examine the macro photographs.
• Read the relevant questions in relationship to each
photograph
• Indicate your answers with an “X” in the appropriate boxes

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in the appropriate column.
• All answers to be marked in pencil. Final answers to be
marked in INK
 Macro Inspection Examination
3. Compare Against Acceptance Levels
1. Examine the Macro Photograph TWI 09 Exam Acceptance Levels for Plate, Pipe and Macro

D=Depth L=Length H=Height t =Thickness

Acceptance Levels

TableNumber

Defect Type
Acceptance levels Plate and Pipe Macro Only

Remarks Maximum Allowance Remarks

2. Read the Questions 1

Excess Weld
Metal
At no point shall the excess weld
metal fall below the outside surface
of the pipe. All weld runs shall blend
smoothly.
Slag inclusions are defined as non
metaltic inclusions trapped in the
Excess weld metal will not exceed H= 2mm in any
area on the circumference of the pipe, showing
smooth transition at weld toes.
The length of the slag inclusion shall not exceed
50mm. continuous or intermittent. Accumulative
As for plate and pipe

Slag/Silica
2 weld metal or between the weld totals shall not exceed 50mm 1mm diameter
Inclusions
metal and the parent material.
Under cut is defined as a grove The length of any undercut shall not exceed 50mm
melted into the parent metal, at the continuous or intermittent. Accumulative totals shall
3 Undercut toes of the weld excess metal, root or not exceed 50mm. Max D = 2mm for the excess
0.5mm deep
adjacent weld metal. weld metal. Root undercut not permitted.
Trapped gas, in weld metal,
Individual pores ≥ 1.5 max.Cluster porosity 10mm in
elongated, individual pores, cluster
4 Porosity area.Elongated, piping or wormholes
porosity, piping or wormhole

1. What is the defect at position 1 and would

15mm max. L continuous or intermittent. 1mm diameter
porosity.

Transverse, longitudinal, star cracks

5 Cracks Not permitted Not permitted
or crater cracks.
Incomplete fusion between the weld Surface breaking lack of side wall fusion, lack of
.
metal and base material, incomplete inter-run fusion continuous or intermittent not to
Lack of fusion between weld metal. (lack of exceed 25mm. Accumulative totals not to exceed
6 Not permitted

you accept or reject the defect to the given

fusion inter-run fusion) 25mm over a 300mm length of weld.
Damage to the parent material or
weld metal, from an un-intentional
touch down of the electrode or arcing Not permitted
7 Arc Strikes
from poor connections in the welding Not permitted
circuit.
Damage to the parent material or

acceptance levels
Mechanical weld metal, internal or external
8 Max. D = 0.5 Not permitted
Damage resulting from any activities.
Mismatch between the welded or un- Max.= 1.5 L not exceed 30mm continuous or
Misalignmen
9 welded joint. intermittent As for plate and pipe
t
Excess weld metal, above the base
material in the root of the joint. At no
Max H ≤ 2mm
10 Penetration point shall the penetration fall below As for plate and pipe
the thickness of the material.
Lack of root The absence of weld metal in the root
area. Refer to Table 10 Not permitted
11 penetration

a) Poor toe blend

Lack of root Inadequate cross penetration of both Lack of root fusion, not to exceed 50mm total
12
fusion root faces. continuous or accumulative. No t permitted

Burn
13 through Excessive penetration , collapse of
Not permitted Not permitted
the weld root

b) Undercut
4. Indicate your Answer
c) Lack of fusion

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Macro 1
d) Incomplete filled groove A B C D X E F X
e) Accept A B C D E F

f) Reject A B C X D E F

A B C D E F

A B C D X E F X
A B X C D E X F

A B C D E F
 Macro Training Sample 1.
2. The area identified at position 2 is referred to as the?
a. Fusion zone
b. Fusion boundary
c. Toe of the weld
d. Under cut

3. The area identified at position 3 is referred to as the?

a. Fusion boundary
b. Acid marks
c. Polished area
d. Heat affected zone
Welding process MMA (SMAW)
4. What is the indication at position 4 and would you
1. What is the indication at position 1 and would accept or reject the indication to the given

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you accept or reject the indication to the given acceptance levels?
acceptance levels? a. lack of inter run fusion
a. Slag inclusions b. fusion boundary
b. Porosity c. lack of side wall fusion
c. Excessive grain size d. linear crack
d Tungsten inclusions e. Accept
e. Accept f. Reject
f. Reject
 Macro Training Sample 1.

6. What is the indication at position 6 and would you

accept or reject the indication to the given
acceptance levels?
a. Slag inclusion
b. Lack of root fusion
c. Lack of root penetration
d. Burn through
e. Accept
f. Reject

7. What is the indication at position 7 and would you

Welding process MMA (SMAW) accept or reject the indication to the given
acceptance levels?
5. What is the indication at position 5 and would you

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accept or reject the indication to the given a. Lack of inter run fusion
acceptance levels? b. Lack of side wall fusion
c. Crack
a. Gas cavity
d. Porosity in the root
b. Lack of side wall fusion
e. Accept
c. Slag trapped at the toes of the weld
f. Reject
d. Lack of inter run fusion and slag
e. Accept
f.Reject
 Macro Training Sample 1.
9. What is the indication at position 9 and would you
accept or reject the indication to the given
acceptance levels?
a. Overlap
b. Toe of the weld with good transition
c. Toe of the weld with poor transition
d. Undercut at the toe of the weld
e. Accept
f. Reject

10. Which term best describes this welded joint?

Welding process used MMA (SMAW) a. Square edge butt joint
b. Double v butt joint
8. What is the indication at position 8 and would you

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c. Single v butt joint
accept or reject the indication to the given
d. T butt fillet weld
acceptance levels?
a. lamellar tearing
b. Hydrogen cracks
c. Laminations
d. Stress cracks
e. Accept
f. Reject
 Macro Training Sample 2.

2. What is the indication at position 2 and would you

accept or reject the indication?
a. Undercut
b. Poor toe blend
c. Incomplete filled groove
d. Lack of sidewall fusion
e. Accept
f. Reject

3. What is the indication at position 3 and would you

accept or reject the indication?
Welding process used MMA (SMAW)
a. Lamellar tearing

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1. What is the indication at position 1 and would you b. Corrosion crack
accept or reject the indication to the given c. Hydrogen crack
acceptance levels? d. Lamination
a. Poor toe blend e. Accept
b. Undercut f. Reject
c. Lack of interun fusion
d Weld boundary
e. Accept
f. Reject
 Macro Training Sample 2.

5. What is the indication at position 5 and would you

accept or reject the indication to the given
acceptance levels?
a. Toe crack
b. Hydrogen crack
c. Overlap
d. Lamellar tearing
e. Accept
f. Reject

Welding process MMA (SMAW) 6. What is the indication at position 6 and would you
4. What is the indication at position 4 and would you accept or reject the indication to the given

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accept or reject the indication to the given acceptance levels?
acceptance levels? a. Spatter
a. lack of inter run fusion b. Lap
b. Lack of side wall fusion c. Overlap
c. Weld boundary d. Hydrogen crack
d. Lack of side wall fusion with associated slag e. Accept
inclusion f. Reject
e. Accept
f. Reject
 Macro Training Sample 2.
8. The area identified at position 8 is referred to as?
a. Heat affected zone
b. Fusion boundary
c. Fusion zone
d. Polished area

9. The area identified at position 9 is referred to as?

a. Heat affected zone
b. Fusion boundary
c. Fusion zone
d. Polished area
Welding process MMA (SMAW)
10. What is the indication at position 10 and would you
7. What is the indication at position 7 and would you accept or reject the indication?

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accept or reject the indication to the given a. Slag line
acceptance levels? b. Overlap
a. Gas cavity c. Lamination
b. Silica inclusion d. Lamellar tearing
c. Slag inclusion e. Accept
d. Copper inclusion f. Reject
e. Accept
f. Reject
 Macro Training Sample 3.
2. What is the indication at position 2 and would you
accept or reject the indication?
a. Saw marks
b. Lamellar tearing
c. Segregation bands
d. Laminations
e. Accept
f. Reject

3. What is the indication identified at position 3 and

would you accept or reject the indication?

Welding process MIG/MAG (GMAW) a. Mechanical damage

b. Lapping

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1. What is the indication at position 1 and would you c. Arc strike
accept or reject the indication to the given d. Lamellar tearing
acceptance levels? e. Accept
a. Linear crack f. Reject
b. Overspill
c. Overlap
d Lamination
e. Accept
f. Reject
 Macro Training Sample 3.
5. What is the indication at position 5 and would you
accept or reject the indication to the given
acceptance levels?
a. Slag
b. Silica
c. Spatter
d. Copper
e. Accept
f. Reject

6. What is the indication at position 6 and would you

Welding process MIG/MAG (GMAW) accept or reject the indication to the given
acceptance levels?
4. What is the indication at position 4 and would you a. Overlap

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accept or reject the indication to the given b. Crack
acceptance levels? c. Incomplete root penetration
a. Lack of side wall fusion with associated slag d. Incomplete root fusion
b. Hydrogen crack e. Accept
c. Lack of side wall fusion with an associated gas f. Reject
cavity
d. linear side wall crack
e. Accept
f. Reject
 Macro Training Sample 3.
8. What is the indication at position 8 and would you accept or
reject the indication to the given acceptance levels?
a. Lack of inter-run fusion
b. Crack
c. Linear slag line
d. Lack of side wall fusion
e. Accept
f. Reject

9. What is the indication at position 9 and would you accept or

reject the indication to the given acceptance levels?
a. Slag inclusion
b. Silicon inclusion
c. Gas cavity
Welding process MIG/MAG (GMAW) d. Shrinkage defect
e. Accept
7. What is the indication at position 7 and would you

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f. Reject
accept or reject the indication to the given
acceptance levels?
10. What is the indication at position 10 and would you
a. Transverse crack
accept or reject the indication?
b. Lack of sidewall fusion
a. Porosity
c. Lack of interun fusion
b. Slag inclusion in the weld metal
d. Shrinkage crack
c. Silicon inclusion in the weld metal
e. Accept
d. Tungsten inclusion
f. Reject
e. Accept
f. Reject
 Macro Training Sample 4.

2. What is the indication at position 2 and would you

accept or reject the indication?
a. Overlap
b. Weld toe with good transition
c. Weld toe with poor transition
d. Undercut
e. Accept
f. Reject

3. What is the indication at position 3 and would you

accept or reject the indication?
Welding process MMA (SMAW)
a. Undercut
b. Poor toe blend

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1. What term best describes this welded joint?
c. Underfill
a. Square edge butt joint d. Lack of side wall fusion
b. Double-V butt joint e. Accept
c. Single-V butt joint f. Reject
d. Double-bevel butt joint
 Macro Training Sample 4.
5. What is the indication at position 5 and would you
accept or reject the indication to the given
acceptance levels?
a. Silicon inclusion
b. Lack of side wall fusion with associated slag
inclusion
c. Gas cavity
d. Gas cavity and lack of side wall fusion
e. Accept
f. Reject

Welding process MMA (SMAW) 6. What is the best term to describe the area identified
at position 6?
4. What is the indication at position 4 and would you

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accept or reject the indication to the given a. Shrinkage
acceptance levels? b. Linear distortion
c. Angular distortion
a. lack of inter run fusion
d. Short transverse distortion
b. Lack of side wall fusion with slag
e. Accept
c. Weld boundary
f. Reject
d. Lack of side wall fusion with silicon
e. Accept
f. Reject
 Macro Training Sample 4.
8. What is the indication at position 8 and would you
accept or reject the indication to the given acceptance
levels?
a. Crack
b. Lack of inter-run fusion
c. Lack of side wall fusion
d. Fusion boundary
e. Accept
f. Reject

9. The area identified at position 9 is referred to as?

a. The heat affected zone
Welding process MMA (SMAW) b. Fusion boundary
c. Fusion zone
d. Polished area

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7. What is the indication at position 7 and would you
accept or reject the indication to the given
10. What is the indication at position 10 and would you
acceptance levels?
accept or reject the indication?
a. Silicon inclusion a. Lamellar tearing
b. Slag inclusion b. Hydrogen cracks
c. Lack of interun fusion with associated slag c. Laminations
d. Elongated gas cavities d. Stress cracks
e. Accept e. Accept
f. Reject f. Reject
 Macro Training Sample 5.
2. What is the indication at position 2 and would you
accept or reject the indication?
a. Lamellar tearing
b. Hydrogen cracks
c. Laminations
d. Stress cracks
e. Accept
f. Reject

3. What is the indication at position 3 and would you

accept or reject the indication?
Welding process MMA (SMAW) a. Undercut
1. What is the indication at position 1 and would you b. Poor toe blend

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accept or reject the indication to the given c. Toe crack
acceptance levels? d. Lack of side wall fusion
e. Accept
a. Mechanical damage
f. Reject
b. Lapping
c. Arc strike
d. Lamellar tearing
e. Accept
f. Reject
 Macro Training Sample 5.
5. What is the indication at position 5 and would you
accept or reject the indication to the given
acceptance levels?
a. Lack of inter-run fusion
b. Fusion boundary
c. Lack of side wall fusion
d. Linear crack
e. Accept
f. Reject

6. What is the indication at position 6 and would you

Welding process MMA (SMAW) accept or reject the indication to the given
acceptance levels?
4. What is the indication at position 4 and would you

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accept or reject the indication to the given a. Lack of side wall fusion with slag
acceptance levels? b. Hydrogen crack
c. Lack of side wall fusion and gas cavity
a. Undercut
d. Linear side wall crack
b. Poor toe blend
e. Accept
c. Underfill
f. Reject
d. Lack of side wall fusion
e. Accept
f. Reject
 Macro Training Sample 5.
8. The are identified at position 8 is referred to as
the?
a. Fusion boundary
b. Acid etching marks
c. Polished area
d. Heat affected zone

9. The are identified at position 9 is referred to as?

a. The heat affected zone
b. Fusion boundary
c. Fusion zone
Welding process MMA (SMAW) d. Polished area
7. Which term best describes the area identified at

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10. Which term best describes this welded joint?
position 7
a. Square edge butt joint
a. Shrinkage
b. Double v butt joint
b. Linear misalignment
c. Single v butt joint
c. Short transverse distortion
d. T butt fillet weld
d. Transition weld set-up
e. Accept
f. Reject