Welding Inspection, Steels -WIS 5

Name: ______________________ Date: ___________

Multi -Choice Question Paper (MSR-WI-1)

Gadamsetti
1. Which of the following butt-weld preparations is b. The weld metal and parent metal.
usually the most susceptible to lack of sidewall c. The boundary between the fusion zone and
fusion during the manual metal arc process? the HAZ.
a. A double-U butt. d. The part of the weld, which has undergone
b. A single-V butt. metallurgical changes due to the heat from
c. A double-V butt. welding.
d. It is not normally a defect associated with the
MMA welding process. 9. The strength of a fillet weld is primary
controlled by:
2. What is the leg length of a fillet weld? a. Leg length.
a. The distance from the toe to face. b. Throat thickness.
b. The distance from the root to face centre. c. Weld thickness.
c. The distance from the root to the toe. d. All of the above.
d. The distance from toe to toe.
10. A crater crack may also be termed:
3. What is the throat thickness of a fillet weld (equal a. Cold crack.
leg lengths)? b. Tearing.
a. The distance from the toe to the face. c. Fatigue crack
b. The distance from the root to the face centre. d. Star crack.
c. The distance from the root to the toe.
d. The distance from toe to toe. 11. Which of the following welding
processes/technique is likely to be used for the
4. Lap joints contain: repair welding of localised porosity in a butt
a. Fillet welds. weld?
b. Corner joints. a. MMA, PG position.
c. Butt-welds. b. Mechanised MAG.
d. Single-bevel butts. c. Submerged arc.
d. All of the above.
5. A duty not normally undertaken by a welding e. None of the above.
inspector is to:
a. Check the condition of the parent material.
b. Check the condition of the consumables.
c. Measure residual stress. 12. Which of the following welds would be
d. Check calibration certificates. considered in a situation where two plates are to
be joined that overlap (assume no external
6. Under most conditions, which of the following assess).
welding positions will deposit the most weld a. A fillet weld.
metal. b. A single-bevel butt weld.
a. Vertical down. c. A plug weld.
b. Overhead. d. A single-U butt weld.
c. Horizontal-vertical.
d. Flat (down hand) 13. In the MMA welding process, which of the
7. What meant by the term crater pipe: following is most likely to be caused by a
a. Another term for concave root welder with a poor technique?
b. Another term given for a burn through. a. Deep weld craters/crater cracks.
c. A type of gas pore, found in the weld crater. b. Copper inclusions
d. A shrinkage defect, found in the weld crater. c. Hydrogen cracks
d. All of the above.
8. What is meant by the term weld junction?
a. The area containing the HAZ and the weld 14. Root concavity is caused by:
metal.

Gadamsetti
a. Excessive back purge pressure and entrapped 20. What is the term given for the area of a welded
gas. joint just outside the weld metal that has
b. Excessive back purge pressure and very high undergone micro-structural changes?
heat inputs. a. Heat affected zone.
c. Excessive root grinding and a slow travel b. The weld zone.
speed. c. Fusion zone.
d. Excessive root grinding and excessive back d. All of the above terms may be used.
purge pressure.
21. When carrying out visual inspection, which
15. When inspecting a critical component, the toes of defect (s) is likely to be missed?
a weld must be: a. Linear misalignment.
a. Always ground flush. b. Cap undercut.
b. Must always overlap at least 1.5 mm onto the c. Porosity.
parent material. d. Lack of fusion (inter run).
c. Must always be inspected using a crack
detection method (MPI, DPI). 22. Cold lapping is another term for:
d. None of the above can be selected - a. Lack of fusion at the toe of a weld.
specification requirements unknown. b. Lack of fusion between weld metal and weld
metal.
16. When carrying out visual inspection, the c. Undercut at the toe of a weld.
specification makes no mention of the d. Both a and b.
requirements for visual inspection, in this situation
what should you do? 23. Incomplete root penetration is most likely due
a. Carry out normal visual inspection. to:
b. Seek advice from higher authority. a. Welding speed too slow.
c. Carry out no visual inspection. b. Welding current too high.
d. Re-write the requirements of the specification. c. Root gap too small.
d. Electrode diameter too small.
17. Under most circumstances, which of the following
do you consider to be duties of a welding 24. Crater cracks are caused mainly by:
inspector? a. Excessively fast welding speeds
a. The supervision of welders. b. Improper electrode angle
b. Procedure writing. c. Hot shrinkage.
c. Qualifying welders d. Improper joint design.
d. All of the above. 25. On a single-V butt weld, the distance through
the centre of the weld from root to face is called:
18. Which of the following is most likely to cause a a. Reinforcement.
burn through b. Penetration.
a. Root gap too small. c. Throat thickness.
b. Travel speed too fast. d. None of the above.
c. Root face too small
d. All of the above. 26. The throat thickness of a % inch fillet weld is?
a. 27.5 mm
19. In an arc welding process, which of the following b. 24 mm.
is the correct term used for the amount of weld c. 13.5 mm.
metal deposited per minute? d. 12.5 mm.
a. Filling rate.
b. Deposition rate. 27. The need for pre-heat for steel will increase if:
c. Weld deposition. a. The material thickness reduces.
d. Weld duty cycle. b. Faster welding speeds
c. The use of a larger welding electrode.

Gadamsetti
d. All of the above.
5. Which of the following processes joins metals
28. Which of the following butt weld preparations is plastically?
most likely to be considered for the welding of a a. Friction welding.
6mm thick plate? b. Resistance welding.
a. Double-V butt. c. Arc welding.
b. Asymmetrical double-V butt. d. Plasma welding.
c. Single-U butt. e. All of the above.
d. Single-V butt.
6. What type of power source characteristic is
29. A welding inspectors main attributes include: required for a manual process?
a. Knowledge. a. Constant voltage.
b. Honesty and integrity. b. Flat characteristic.
c. Good communicator. c. Drooping characteristic.
d. All of the above. d. None of the above.

30. A code of practice for visual inspection should 7. Which of the following electrodes and current
cover: types may be used for the TIG welding of nickel
a. Before, during and after welding. and its alloys?
b. Before welding activities only. a. Cerium electrode, DC -ve.
c. After welding activities only. b. Zirconium electrode, AC.
d. None of the above. c. Thorium electrode, DC +ve.
d. All of the above may be used.
Multi -Choice Question Paper (MSR-WI-2)
8. What are the possible results of having a heat
1. Defects outside the permissible limits of the
input to low?
applicable specification should be:
a. An increase in hardness, lower yield
a. The decision is up to the welding inspector.
strength and lack of fusion.
b. Repaired.
b. A reduction in toughness, hydrogen
c. Always double checked using NOT.
entrapment and an increase in hardness.
d. All of the above.
c. Entrapped hydrogen, an increase in hardness
and lack of fusion
2. Electrodes used in manual metal arc welding can
d. Entrapped hydrogen, a reduction in carbon
be grouped into three main types, these are:
content and lack of fusion.
a. Oxidising, basic and rutile.
b. Cellulose, basic and acidic.
c. Granular, rutile and basic.
9. The main reason for using a back purge when
d. Rutile, basic and cellulose.
welding 18-8 stainless steel with the TIG
welding process is to:
3. Movement of the arc by magnetic forces in an arc
a. Improve positional welding.
welding process is termed:
b. Prevent the possibility of porosity.
a. Arc deviation.
c. Prevent excessive root penetration
b. Arc misalignment.
d. Prevent the formation of a dense oxide layer
c. Arc blow.
forming in the root.
d. Stray arc.
10. The possible effects of having a travel speed too
4. A crack type most associated with the submerged
fast:
arc welding process is:
a. Low toughness, slag inclusions and cap
a. Hydrogen cracking in the HAZ.
undercut.
b. Solidification cracking.
b. High hardness, slag inclusions and a narrow
c. Lamellar tearing.
thin weld bead.
d. Fatigue cracking.
Gadamsetti
c. High hardness, excessive deposition and cold d. GMAW.
laps
d. Low toughness, poor fusion and slag 16. When considering the tungsten arc welding
inclusions. process what is the purpose of the down-slope
(slope-out) control?
11. If arc blow exists when welding with the MMA a. Ensure good penetration.
welding process, this can be best reduced or b. To prevent arc striking on the parent
eliminated by: material.
a. A change from AC to DC current. c. To help prevent the formation of crater pipe
b. A change from DC to AC current. and possible cracking.
c. A change from DC +ve to DC -ve. d. To help prevent tungsten inclusions during
d. A change from DC -ve to DC +ve. welding.

12. When welding a double-V butt weld with the 17. When considering thermal cutting local
submerged arc welding process the presence of hardening can be reduced by:
centre line porosity may be due to: a. Increasing the cutting speed.
a. Damp flux. b. The use of propane as a fuel gas.
b. Contamination on the weld preparations. c. Pre heating the material to be cut.
c. Incorrect flux depth d. All of the above.
d. All of the above.
18. In a semi-automatic welding process, which of
13. The inclusion of an inductance in the welding the following shielding gas/gas mixtures would
circuit when using MIG/MAG welding process is normally give the deepest penetration on steel?
to: a. 100% argon.
a. Control the rate of spatter in the dip transfer b. 100% CO2.
mode. c. 75% argon + 25% CO2.
b. It enables the welder to weld in position with d. All of the above would give the same depth
the spray transfer mode. in penetration.
c. It allows for thicker filler wires to be used
(2.6-3.6mm diameter).
d. It allows full control over droplet size in the
spray transfer mode.

19. In a MMA welding process, which of the

following statements are false?
a. An arc gap, which remains almost constant
14. An undesirable property of aluminium oxide even if as usual the welder varies the
residue, when welding is that it: position of the electrode.
a. Decrease weld pool fluidity. b. A voltage, which remains almost constant
b. Requires more heat to melt it when compared even if as usual the welder, varies the arc
to aluminium. gap.
c. Causes the welder to travel to quickly. c. A current, which remains almost constant
d. The presence of the oxide makes aluminium even if as usual the welder, varies the arc
impossible to weld. gap.
d. A and b.
15. Which of the following welding process is most e. All of the above.
likely to be used for the welding of a small
diameter stainless steel pipe, 6mm-wall thickness? 20. Which of the following welding process, after
a. GTAW the weld is completed normally requires a post
b. SMAW. weld heat treatment to restore toughness values
c. Submerged arc welding. ~

Gadamsetti
a. ESW. a. The current will increase.
b. MMA. b. The current will decrease.
c. MAG. c. The voltage will decrease.
d. All completed welds require a post heat d. The voltage will increase.
treatment, regardless of welding process.
27. Which of the following best describes a semi-
21. Which of the following current types would you automatic welding process?
expect to be used for the welding of aluminium a. The welder is responsible for the
with the TIG welding process? maintaining the arc gap and travel speed.
a. DC -ve. b. The welder is responsible for travel speed
b. DC +ve. only; arc gap is kept constant by the welding
c. AC plant.
d. All of the above. c. Both travel speed and arc gap is controlled
by the welding plant
22. Which of the following statements is false? d. All of the above.
a. In the MMA welding process electrode DC +
produces a deep narrow weld pool, which is 28. What is purpose of a rectifier in a welding sets
fast freezing. electrical circuit?
b. DC electrode positive is used for the MAG a. To keep the arc stable when using low
welding of steel plate. current settings
c. The word calcium carbonate means limestone b. To convert AC current to DC current.
d. All of the above c. To convert DC current to AC current.
d. To initiate the arc at start up.
23. When considering hydrogen, which of the
following welding process would produce the
lowest levels in the completed weld (under 29. When calibrating a mechanised MAG welding
controlled conditions) plant, which of the following applies (WFS =
a. MMA. Wire feed speed)?
b. SAW. a. Check -WFS, current, volts and wire
c. TIG. diameter.
d. FCAW. b. Check -WFS, joint set-up, gas flow rate and
WFS.
24. Pre heat prior to the welding of a carbon steel butt c. Check -Gas flow rate, stick out length, WFS
weld: and current.
a. Must always be carried out. d. All of the above.
b. Is always carried out using a gas flame C
c. Need not be carried out if post weld heat 30. The main usage of the arc air process is:
treatment is to follow a. The cutting of a weld preparation.
d. None of the above. b. The removal of defective welds.
c. For the cutting of non-ferrous materials
25. In steel the element with the greatest effect on only.
hardness is: d. For the cutting of ferrous materials only.
a. Chromium.
b. Manganese.
c. Carbon. Multi -Choice Question Paper (MSR-WI-3)
d. Nickel.
1. The likelihood of a brittle fracture in steels will
increase with:
26. For a given voltage and current settings on a
a. The formation of a fine grain structure.
MMA welding plant, when the arc length is
b. A reduction in-service temperature to sub-
shortened, which of the following will be most
zero conditions.
affected.
c. A slow cooling rate.
Gadamsetti
d. All of the above. c. Carbon.
d. Molybdenum.
2. Hydrogen cracking in a weld zone is most likely to
occur when welding: 9. The HAZ associated with a fusion weld:
a. Carbon manganese steels. a. Can not be avoided.
b. Austenitic stainless steel. b. Usually has the highest tensile strength.
c. Micro alloyed steel (HSLA). c. Is usually martensitic.
d. Low carbon steel. d. Both a and b.
e. All of the above.
3. Preheating for arc welding applies to:
a. Assembly and tack welding only. 10. What four criteria are necessary to produce
b. Joint over 25 mm thick only. hydrogen induced cold cracking?
c. Assembly welding only. a. Hydrogen, moisture, martensitic grain
d. When using the MMA welding process only. structure and heat.
e. Both a and b. b. Hydrogen, poor weld profiles, temperatures
above 200°C and a slow cooling rate.
4. Which of the following destructive tests would c. Hydrogen, a grain structure susceptible to
indicate the toughness value of the weld cracking, stress and a temperature below
metal/parent metal and HAZ? 200°C.
a. Macro. d. Hydrogen, existing weld defects, stress and
b. Nick break. a grain structure susceptible to cracking.
c. Tensile.
d. Charpy Vee notch. 11. A carbon equivalent (CE) of 0.5%:
a. Is high for carbon manganese steel and may
5. What constituent is needed in a coating of an require a preheat over 100°C
electrode to prevent the formation of porosity b. Is generally significant for carbon for
when welding rimming steel? manganese steels and is certainly not to be
a. Iron powder. taken into consideration for preheat
b. Potassium silicate. temperatures.
c. Silicon c. Is high for carbon manganese steels and may
d. Calcium carbonate. require a preheat temperature over 300°C as
to avoid cracking
6. Welds made with high heat inputs show a d. Is calculated from the heat input formula.
reduction in one of the following properties?
a. Ductility.
b. Toughness.
c. Elongation. 12. In a martensitic grain structure what would you
d. Penetration. expect to increase?
7. Which of the following steel types would give rise a. Ductility.
to the formation of porosity when autogenously b. Hardness.
welded with an arc welding process c. Toughness.
a. Fully killed steel. d. All of the above.
b. Semi killed steel.
c. Rimming steel. 13. What do you understand by the term minimum
d. Balanced steel. inter-pass temperature?
a. Minimum post weld heat treatment applied
8. Which of the following elements, which may be to a weld.
added to steel, has the greatest affect on creep b. Minimum stress relief temperature.
strength. c. The lowest temperature to be used during
a. Tungsten. preheat.
b. Manganese.

Gadamsetti
d. The lowest temperature allowed during
welding and between weld passes. 20. Which of the following properties may be
applicable to a carbon steel weld (CE 0.48)
14. Which of the following heat treatments on steel welded without preheat?
cools down in air from the austenite region? a. Narrow heat affected zone and hardness
a. Normalising. value in excess of 400 HV.
b. Annealing. b. Broad heat affected zone and hardness
c. Tempering. values in excess of 400 HV.
d. Stress relieving. c. A very tough and narrow heat affected zone.
d. Narrow heat affected zone and low hardness
15. What is the purpose of microscopic examination values.
of a weld?
a. To determine the number and type of defects 21. Which of the following materials is considered
present. to be the easiest to weld?
b. To determine the grain size. a. Mild steel.
c. To determine the strength of the weld. b. Medium carbon steels.
d. Both a and b. c. Martensitic stainless steel
e. All of the above. d. Forging steel.

16. Which of the following units could a tensile 22. Which of the following NOT methods would be
specimen be measured in? best suited for the detection of surface breaking
a. Pounds per square inch. defects on an austenitic stainless steel pipe
b. Newton per square inches. a. MPI.
c. Joules. b. UT.
d. Both a and b. c. DPI.
d. All of the above can be used.
17. Assuming that the welding process, material
thickness, carbon equivalent and the welding 23. Which of the following butt weld preparations
parameters to be the same, which of the following would be considered for a mechanised welding
joint types would normally require the highest process
preheat temperature. a. Single-V butt, root gap 2.5 mm (welded
a. Edge joint. from on side only).
b. Lap joint. b. Double-V butt-welded both sides, root gap
c. Butt joint (single-V). 2.0 mm.
d. Tee joint (fillet welded). c. Single-U butt with backing.
d. None of the above can be used for
mechanised welding.
18. Austenitic stainless steels are more susceptible to 24. Which is the correct heat input for the following
distortion when compared to ferritic steels this is parameters, amps 350, volts 32 and the travel
because: speed 310 mm/minute (MMA welding process)?
a. High coefficient, low thermal conductivity. a. 2.16 kJ/mm.
b. High coefficient, high thermal conductivity. b. 0.036 kJ/mm.
c. Low coefficient, high thermal conductivity. c. 2160 kJ/mm.
d. Low coefficient, low thermal conductivity. d. 3.6 kJ/mm.

19. Which of the following will most likely require the 25. Assuming that the applicable specification
preheat temperature to be increased? makes no mention of arc strikes, what would
a. An Increase in travel speed. you expect to do as a welding inspector if arc
b. A reduction in material thickness strikes were found on a component made of a
c. An increase in electrode diameter. high tensile strength material.
d. None of the above a. Have the welder re-qualified.

Gadamsetti
b. Ignore them. a. It’s a static test used to determine a
c. Have the area checked for possible cracking. material’s notch toughness in the weld
d. Cut out the entire weld where the arc strikes region.
exist. b. It’s a dynamic test used to determine a
material’s notch toughness in the weld
26. A multi-pass MMA butt weld made on carbon region.
steel consists of 5 passes deposited using a 6mm c. It’s a destructive test to give a measurement
diameter electrode. A 12-pass weld made on the of through thickness ductility.
same joint deposited using a 4mm diameter d. None of the above.
electrode on the same material will have:
Multi -Choice Question Paper (MSR-WI-4)
a. A lower heat input and a higher degree of
1. Degreasing components are essential for quality
grain refinement.
welding. but when welded some agent may:
b. A lower heat input and a coarse grain
a. Cause corrosion problems.
structure.
b. Leave residues
c. A lower amount of distortion and a higher
c. Give off toxic gases.
degree of grain refinement.
d. All of the above.
d. A higher amount of distortion and a lower
degree of grain refinement.
2. Cellulose electrodes are often used for the
deposition of a root pass on pipes welded in the
27. What is the purpose of a tensile test?
field. This is because?
a. To measure ultimate tensile strength.
a. Hydrogen control is required.
b. To measure the elongation of a material
b. The high deposition rate due to the iron
c. To measure the yield strength of a material
powder content.
d. All of the above.
c. The hydrogen gas produced in the flux
increases the arc voltage.
28. Which of the following mechanical tests can be
d. All of the above.
used to give a quantitative measurement of weld
zone ductility?
3. In the welding of austenitic stainless steels, the
a. Tensile test.
electrode and plate materials are often specified
b. Bend test.
to be low carbon content. The reason for this:
c. Charpy V notch test.
a. To prevent the formation of cracks in the
d. All of the above.
HAZ.
b. To prevent the formation of chromium
carbides
c. To prevent cracking in the weld.
d. Minimise distortion.
29. Which of the following are reasons for applying
preheat?
a. The removal of residual stress.
4. With regards to a welding procedure, an
b. To aid slow cooling and reduce the carbon
essential variable may:
content.
a. Change the properties of the weld.
c. To reduce the chance of a brittle grain
b. Influence the visual acceptance.
structure and to reduce the chance of hydrogen
c. Require re-approval of a weld procedure.
entrapment.
d. All of the above
d. Increase the ultimate tensile strength values
and increase overall weldability.
5. Which of the following NOT methods can only
detect surface breaking defects?
30. Which of the following are true with regards to a
a. MPI
Charpy test.
b. OPI.
c. UT
Gadamsetti
d. RT. b. Friable slag, high mechanical strength, and
e. Both a and b. to produce welds of a low hydrogen content.
c. Low hydrogen content welds, good
6. Which of the following defects would show up as stop/start properties and high strength.
light indications on a radiograph? d. Low carbon content welds, friable slag and
a. Slag inclusions and copper inclusion. high strength.
b. Tungsten inclusions and excessive root
penetration. 12. On a radiograph, the most likely appearance of
c. Cap undercut and root piping. lack of root fusion on a single-V butt weld is:
d. Excessive cap height and incomplete root a. A dark straight 1ine with a light root.
penetration. b. A dark root with straight edges.
c. A dark uneven line following the edge of the
7. Which of the following electrodes is the most root
likely to contain the largest quantity of d. None of the above lack of root fusion can
combustible organic compounds? not be seen on a radiograph.
a. Basic.
b. Acidic. 13. What do you understand by the term minimum
c. Rutile. interpass temperature?
d. Cellulose. a. Minimum post weld heat treatment applied
to a weld.
8. Lamellar tearing is best prevented by: b. Minimum stress relief temperature.
a. The use of plate materials containing low c. The lowest temperature to be used during
levels of impurities. preheat.
b. The use of buttering runs. d. The lowest temperature allowed during
c. Post weld stress relief. welding and between weld passes.
d. Both a and b.
e. All of the above. 14. Which of the following is applicable to a plate
lamination
9. When considering radiography using X-ray, which a. They are best detected by radiography.
of the following techniques is most likely to be b. They are mainly caused by hydrogen
used for a pipe to pipe weld (circumferential entrapment.
seam), 610mm diameter with no internal access? c. They originate in the parent material.
a. SWSI. d. They are caused when welding stresses act
b. DWSI. parallel with the rolled direction of the
c. DWDI. parent plate.
d. SWSI-panoramic.
15. Which of the following NOT methods would be
the least effective on an austenitic stainless steel
butt weld.
10. A balanced welding technique for example back a. UT.
step welding is most often used for: b. RT.
a. Controlling lamellar tearing. c. OPI.
b. Increasing weld toughness. d. MPI.
c. Reducing weld zone hardness.
d. Reducing distortion. 16. The hardest part of a multi-pass welded joint,
assuming no post weld heat treatment has have
11. Basic coated electrodes have which of the taken place is:
following properties. a. The HAZ of the cap.
a. High mechanical properties may be used to b. The HAZ of the root.
produce welds of high deposition rates and to c. The root.
produce welds of low hydrogen content. d. The cap.

Gadamsetti
b. Resistant spot welding.
17. Is it permissible to allow a single pass butt weld to c. Electro-slag.
cool down between weld passes? d. Friction welding.
a. It should be up to the welding inspector.
b. No the weld must be kept hot at all times. 23. What does the 70 represent on an E70 10 AWS
c. It depends on the welder A5.1 classified electrode?
d. It depends on the specification requirements. a. 70 N/mm2 minimum UTS.
b. 70 joules minimum impact strength.
18. A tee joint on a support bracket is to be welded c. 70,000 p.s.i. Minimum yield strength.
both sides using a 5 mm leg length fillet weld, d. 70,000 psi minimum UTS.
each weld is to be intermittent 50 mm in total
length, the gap between each weld is to be 25 mm. 24. Basic electrode provided in a standard
Which of the fallowing is the correct symbol in packaging:
accordance with ISO 2553? a. Should be baked as to manufactures
recommendations prior to use.
b. The baking conditions depend upon the
welder.
c. Are recommended for use where porosity
free welds are required.
d. Are only suitable for welding in the flat,
vertical, and down hand positions.

25. Cellulose electrodes have which of the following

properties?
a. Viscous slag, large volumes of shielding gas
and UTS values above 90,000 psi.
19. The usual method of assessing the sensitivity and b. Large volumes of shielding gas, high spatter
density of a radiograph is by means of: contents and hydrogen levels < 15 ml per
a. Densitometer and dosimeter. 100g of weld metal deposited
b. Penetrameter and a densitometer. c. Large volumes of shielding gas, hydrogen
c. IQI and a dosimeter. contents> 15 ml per 100g of weld metal
d. IQI and a fluxmeter. deposited and should be never baked.
d. High spatter contents, high deposition and
20. In the submerged arc welding process, the use of large volumes of gas shield.
excessive high voltages would result in?
a. Insufficient flux melting. 26. From the following electrode coding E50 4 B
b. Excessive flux melting 160 20 H5, the compulsory part is:
c. Slag removal difficulties. a. E50 3 B 160 20 H5.
d. Excessive spatter. b. B 160 20 H5.
c. E50 4 B.
21. Welding a steel plate with a CE of 0.45 would d. None of the above.
require preheating to?
a. Prevent the formation of sulphides. 27. Which of the following is applicable to electrode
b. Prevent hardening in the HAZ. efficiency?
c. Prevent the formation of carbides. a. The mass of metal deposited as a percentage
d. To reduce the amount of current required. of the mass of core wire melted.
b. Iron powder electrodes have efficiencies
22. Which of the following welding process uses a above 100%.
resistive heating system to achieve weld metal c. Electrodes of high efficiencies tend to
deposition? produce welds of a smooth flat profile.
a. MMA d. Both a and b.

Gadamsetti
e. All of the above. b. High-pressure pipe work.
c. Vertical down welding on storage tanks.
28. A Fatigue cracks fracture surface is: d. In a situation where low hydrogen welds are
a. Rough randomly torn. specified.
b. Smooth.
c. Step like appearance. 30. Which element in steel if present in significant
d. Bright crystalline. amounts may lead to hot shortness?
a. Phosphorus.
29. E6014 electrode would most probably used for b. Manganese.
welding: c. Silicon.
a. Low pressure pipe work. d. Sulphur.

Gadamsetti
WELDING INSPECTION, STEELS -WIS 5
MULTI-CHOICE QUESTION PAPER (MCQ.004 & MCQ.001+Own)
Name: _______________________________
Answer all questions
1. Movement of the arc by magnetic forces in
MMA welding is termed: 7. Which of the following coatings is associated
a) Arc deviation with “Stove” welding:
b) Arc misalignment a) Rutile
c) Arc blow b) Cellulosic
d) Arc eye c) Basic V
d) Oxidising
2. A metallurgical problem most associated with 8. A common gas/mixture used in MIG welding
submerged arc welding is : nickel alloys to combine good levels of
a) Hydrogen cracking in the HAZ penetration with good arc stability would be:
b) Solidification cracking in the weld metal a) 100% Carbon dioxide
c) Hydrogen cracking in the weld metal b) 100% argon
d) Lamellar tearing in the weld metal c) 80% argon 20% Carbon dioxide
d) 98% argon 2% oxygen
3. Oxy pressure and nozzle size would influence
what in flame cutting: 9. The type of SAW flux is more resistant to
a) The temperature required for cut initiation moisture absorption:
b) The ability to cut stainless steels a) Fused
d) V The depth of cut obtainable b) Agglomerated
d) None of the above c) Basic
d) All of about the same resistance
4. The main usage of arc cutting/gouging
processes is in: 10. The flame temperature of oxy/acetylene
a) The cutting of single bevel preparations mixture gas is given as:
b) The removal of deposited welds a) 3200°C
c) The cutting of single U-type preparations b) 2 300 °C
d) The cutting/gouging of non-ferrous materials c) 5000°C
only d) None of the above

5. Which of the following processes joins metals 11. A large grain structure in steels is said to
plastically: produce:
a) Friction Welding a) Low ductility values
b) Resistance Welding b) Low fracture toughness values
c) Plasma Welding c) High fracture toughness values
d) All of the above d) High tensile strength

6. Which electrode classification would be 12. The likelihood of brittle fracture in steels will
relevant to AWS A5.1 – 81: increase with:
a) E6013 a) A large grain formation
b) E 5133 b) A reduction of in-service temperature to sub
c) E7018–G zero levels
d) Fleetweld 5 c) Ferritic rather than austenitic steels

Gadamsetti
d) All the above 19. The process of tempering is often carried out
to regain toughness after which of the following
13. Repair welding is often more difficult than processes:
production due to: a) Annealing
a) The material being ingrained with in-service b) Normalising
contaminates c) Hardening
b) Restricted access within the repair area d) Stress relieving
c) The possible position of the weld repair
d) Any of the above 20. The presence of iron Sulphide in the weld
metal is most likely to produce which of the
14. Hydrogen cracking in the weld metal is likely following upon contraction of the weld:
when welding: a) Solidification cracking
a) Carbon manganese steels b) Hydrogen cracking
b) Stainless steels c) Intergranular corrosion
c) Micro alloyed steels (HSLA) d) Stress corrosion cracking
d) Low carbon steels
21. When "hydrogen control" is specified for a
15. EN standard 288 would refer to which of the manual metal arc welding project the electrode
following: would normally be:
a) Welder approval testing a) Cellulosic?
b) Welding equipment b) Iron oxide?
c) Welding procedure approval c) Acid?
d) Consumables for submerged arc welding d) Basic?

16. Porosity is caused by:

a) Entrapped slag in the solidifying weld 22. You would with certainty recognise a
b) Entrapped gas in the solidifying weld hydrogen controlled flux covered electrode from
c) Entrapped metallic inclusions in the solidifying its:
weld a) Colour?
d) None of the above b) Length?
c) Trade Name?
17. In a bend test, the face of the specimen is in d) AWS/BS639 Code Letter?
tension and root is in compression; the type of test
being carried out would be: 23. When manual metal arc welding is being
a) A root bend test carried out on an open construction site, which
b) A side bend test group of welders are the most likely to require
c) A face bend test continuous monitoring?
d) None of the above a) Concrete shuttering welding teams?
b) Pipe welding team?
18. Ultrasonic testing is of advantage in detecting c) Plater welders?
which of the following weld imperfections over d) Plant maintenance welders?
other NDT methods:
a)Lack of side wall fusion 24. You notice manual metal arc electrodes,
b) Surface undercut stripped of flux, are being used as filler wire, for
c) Incompletely filled groove TIG welding. You would object because:
d) Overlap a) It is too expensive ?
b) The wire would be too thick?
c) The weld metal composition may be wrong?
d) The wire is too short ?

Gadamsetti
25. When open site working, serious porosity in 31. For open site manual metal welding the
metal arc welds is brought to your attention. What following equipment is available. Which would
would you investigate? you choose for safe working?
a) Electrode type? a) Single operator transformer?
b) Power plant type? b) Multi operator transformers?
c) Electrode storage? c) AC/DC composite power unit?
d) Day temperature? d) Diesel engine driven motor generator?

32. If submerged arc welding is to be used to

26. The steel composition in a structural contract make butt welds, which would you be most
is changed from 0.15% carbon, 0.6% manganese, critical of:
to 0.2% carbon, 1.2% manganese. Might this a) The root-gap tolerance?
influence the incidence of : b) The angle of-preparation?
a) Porosity ? c) The root face width?
b) Cracking in the weld area? d) The gas cut finish?
c) Undercut for fillet welds?
d) Lack of root fusion defects? 33. During CO2 welding, the arc length is most
likely to be affected by :
a) The wire diameter?
27. One of the following alloys is non-magnetic b) The current return connections?
Which? c) The gas flow rate?
a) 4.0% Chromium molybdenum d) The torch to work angle?
b) 12.0% Chromium
c) Austenitic Stainless Steel 34. Preheating for arc welding applies to :
d) 9.0% Nickel Steel a) Assembly welding only?
b) Assembly and tack welding?
28. When TIG welding Austenitic stainless steel c) Joints over 25mm thick only?
pipe, Argon gas backing is called for. d) Cruciform welds only?
This is to :
a) Prevent oxidation?
b) Prevent underbead cracking? 35. You see a welder using an oxy-acetylene
c) Prevent porosity ? flame with a long feathered inner cone. What
d) Control the penetration bead shape? would be the effect of this on a carbon steel.
a) The weld could be hard and brittle?
29. Pre-heating a Carbon steel manual metal arc b) The weld metal could be too soft ?
welding is carried out to minimise the risk of: c) There will be no effect on the weld?
a) Scattered porosity ? d) The weld will have undercut?
b) Worm hole porosity?
c) Parent metal cracking? 36. A welder qualification test is to verify :
d) Lack of penetration? a) The skill of the welder?
b) The quality of the materials?
30. In UK practice, BS499 Part 2 specifies that c) The non-destructive test procedures?
the drawing dimension quoted for a fillet weld is d) The manufacturing methods?
the:
a) Leg length? 37. A fabricating procedure calls for fillet welds
b) Actual throat thickness? / to be "blended in" by grinding. This is to
c) Weld width? influence:

Gadamsetti
a) H.A.Z. cracking? d) None of the above
b) Fatigue life?
c) Residual stress? 44. A change in supplementary essential variables
d) Yield strength? requires requalification, when notch- toughness is
a consideration.
38. Bend test specimens have been taken from a a) True
25mm thick carbon steel butt weld. Which would b) False
show lack of inter-run fusion:
a) Side bend? 45. The term used to describe lack of fusion in a
b) Root bend? casting is ------------.
c) Face bend? a) Chill
d) Guided bend? b) Fin
c) Cold shut
39. Lamellar tearing has occurred in a steel d) Shrinkage cavity
fabrication. BEFORE welding could it have been
found by : 46. In the welding of austenitic stainless steels,
a) X-ray examination? the electrode and the plate material can be
b) Dye penetrant? purchased with low carbon contents. The reason
c) Ultrasonic inspection? for this is to prevent?
d) It would not have been found by any inspection a) Cracking in the HAZ
method? b) The formation of chromium carbides
c) Cracking in the weld metal
40. You are to oversee the arc welding of some d) Distortion
machined fittings and find they are cadmium
plated. Would you: 47. The marking of a reject able weld should.
a) Permit it to proceed? a) Be clear and understandable to all involved
b) Permit it to proceed with fume extraction? b) Be made with a steel impression stamp
c) Stop the operation at once? c) Note the proper repair procedure
d) Advise the welder to drink milk and proceed? d) Always be in red
e) Always include the welder’s identification.
41. Heating a metal to 550-650°C, holding and
cooling in air would be defined as --------. 48. You see a welder using an oxy-acetylene
a) Annealing flame with long feathered inner cone. What would
b) Normalizing be the effect of this on carbon steel?
c) Sub-critical annealing a) The weld could be hard and brittle.
d) Stress relieving b) The weld metal could be too soft.
c) There will be no effect on weld metal
42. The welding inspector’s duties should include. d) The weld will have undercut
a) Verification of base material
b) The verification of a weld filler metal type 49. Oxygen pressure and nozzle size would
c) The development of weld repair procedures influence what in flame cutting
d) a and b above a) the temperature required for cut initiation
e) b and c above b) the ability to cut stainless steels
c) the depth of cut obtainable
43. A fatigue failure is characteristic by the d) all of the above
appearance of the fracture surface. It would be:
a) Rough and torn 50. An austenitic stainless steel may suffer :
b) Cheveron – like a) Weld decay
c) Smooth b) Sensitization

Gadamsetti
c) Solidification cracking 57. Solidification cracks occur most commonly
d) All of the above in which part of weld?
a) Parent material
51. In the construction of a welding symbol, the b) HAZ
basic element is the. c) Weld centre line
a) Arrow d) Any of the above
b) Reference line
c) Weld symbol 58. As tempering temperature increase:
d) None of the above a) hardness increases
b) hardness decreases
52. The steel composition in a structural contract c) elongation decreases
is changed from 0.15% carbon, 0.6% manganese, d) b and c above
to 0.2% carbon, 1.2% manganese. Might this
influence the incidence of ----------------. 59. Brazing differs from welding in that.
a) Porosity a) No tiller metal is used
b) Cracking in the weld area b) An oxyfuel flame is used
c) Undercut for fillet welds c) The base metal is not melted
d) Lack of root fusion defects d) All of the above

53. What constituent is needed in a coating of an 60. What type of power source characteristic is
electrode to prevent the formation of porosity in required for SMAW?
welding of rimming steel? a) Constant Voltage
a) Iron powder b) Flat characteristic
b) Calcium fluoride c) Drooping characteristic
c) Silicon d) Motor generator
d) Calcium carbonate
61. The size of the a spot weld is determined by
54. Which of the following alloys is non- its:
magnetic? a) depth of fusion
a) 4.0% chromium molybdenum b) spot diameter
b) 12.0% chromium c) depth of penetration
c) Austenitic stainless steel d) thickness
d) 9.0% nickel steel
62. The carbon content of cast iron is
55. When welding aluminum with the GTAW approximately.
process, what type of welding current is most a) 1%
commonly used? b) 2%
a) DCEP c) 0.5%
b) DCEN d) 3%
c) AC
d) Both a & b above 63. For concave fillet weld, which throat
dimensions is the same?
56. Ultraviolet light is utilized with which NDT a) theoretical and effective
method? b) effective and actual
a) VT c) theoretical and actual
b) PT d) none of the above
c) MT
d) b and c above

Gadamsetti
64. When hydrogen control is specified for a b. UT
SMAW project the electrode would normally be c. MT
-----------. d. PT
a) Cellulose
b) Iron oxide 70. Which of the following process produces
c) Acid more heat input?
d) Basic a. MMA
b. MIG / MAG
65. A repair organization has a WPS which states c. SAW
it is qualified for P-8 to P-8 material welded with d. TIG
either E308, E308L, E309, E316 electrodes
(SMAW process). The PQR, supporting this 71. Which of the following NDT method is best
WPS, states the weld test coupons were SA-240 suited to detect lamination defects?
type 304L materials, welded with E308 a. RT
electrodes. Is the WPS properly qualified for the b. UT
base material c. MT
listed? d. PT
a) Yes
b) No 72. What will be the result of using excessive
c) Not enough information given voltage in SAW process?
d) Yes, if properly heat treated a. excessive spatter
b. high penetration
66. Which of the following is used for position c. over deposition
welding in MIG / MAG welding? d. burn through
a. Spray Transfer
b. Globular Transfer 73. In SAW process bulk porosities are formed
c. Dip Transfer due to _____.
d. Pulse Transfer a. dampened flux
b. contamination in the bevel
67. What you will do when you notice that the job c. high level flux
you are inspecting is coated with Cd? d. misalignment
a. Stop the welding at once
b. Continue inspection and allow welding 74. Which of the following elements when added
c. Advise the inspector to have a glass of milk and into steel provides corrosion resistance?
proceed with welding. a. Carbon
d. Fume it then continue welding b. Manganese
c. Magnesium
68. What would be the effect on the welding d. Chromium
when the Carbon and manganese content are
changed from 0.15 & 0.6 to 0.2 & 1.2? 75. Which of the following position requires
a. more chances of porosity highest welder skill?
b. more chance of HAZ cracking a. Plate – down hand
c. more under cut b. Fillet weld with plate axis fixed vertically
d. concave cap profile c. Pipe rotated
d. Pipe axis fixed horizontally
69. Which of the following NDT method is most
effective to find out a surface crack in austenitic 76. The bend test performed with root facing
stainless steel? tension side is called ______.
a. RT a. side bend test

Gadamsetti
b. face bend test a. do visual inspection as usual
c. root bend test b. don’t do visual inspection and accept all
d. nick break test c. report to higher authorities and ask advise
d. write visual inspection procedure
77. A low Carbon steel specimen is heat treated to
achieve which of the following? 79. When the specification does not give any
a. minimize the mechanical damage caused by criteria for arc-strike, what will be your action if
further machining you find arc-strikes?
b. to reduce chance of hydrogen cracking a. accept all
c. to reduce stress b. reject all
d. to minimize the distortion c. request MT or PT to make sure there is no
crack.
78.What you will do as an inspector when the d. none of the above.
specification does not specify about the visual
inspection requirement?

Welding Inspection, Steels -WIS 5 Multi -Choice End of Course Assessment

Question Paper (MSR-AWI-1)
Name: __________________________
Answer all questions

1. What is the ratio between the leg length and the b. Their existence will result in the removal of the
design throat thickness on a mitre fillet weld with entire weld.
equal leg lengths c. They are not usually as significant as planar
a. 1:1 defects.
b. 2 : 1 d. They can only be detected using radiography.
c. 1.414 : 1.
d. It depends on the fillet welds dimensions and 5. Lamellar tearing is:
fit up requirements. a. A product defect caused during the
manufacturing of certain steels
2. What is the leg length of a fillet weld? b. A crack type, which occurs in the parent
a. The distance from the toe to face. material due to welding strains acting in the short
b. The distance from the root to face centre. transverse direction of the parent material.
c. The distance from the root to the toe. c. A type of hot crack associated with impurities
d. The distance from toe to toe. (sulphur, carbon and phosphorous).
d. A type of crack that occurs in the weld or
3. Why is the arc shielded, when using an arc parent material due to cyclic stresses.
welding process?
a. To eliminate hydrogen from the arc. 6. The weld zone associated with a welded joint
b. To retard the cooling rate of the solidifying is:
metal. a. Weld metal, HAZ and the parent material in the
c. To excluded the atmosphere from the arc immediate vicinity.
region. b. Weld metal only.
d. The arc is not always shielded when using an c. The weld metal plus parent material.
arc welding process. d. HAZ and parent material.

4. Which of the following is applicable for a none 7. Which of the following elements if present in
planar defects? significant quantities in steel may lead to cold
a. They are always repaired. shortness.

Gadamsetti
a. Sulphur. steel, which of the following problems are likelY
b. Phosphorous. to occur?
c. Silicon. a. Copper inclusion$ and excessive cap heights.
d. Copper. b. Excessive root penetration and porosity.
c. Slag inclusions and crater pipe.
8. A black triangular flag used in conjunction d. Lack of fusion and poor cap profiles.
with a weld symbol as to EN 22553 means:
A specific welding process is required. 14. It is a requirement to excavate a crack in a
b. The weld is to be made under constant welded component; the defect is at least 25 mm in
supervision of a qualified welding inspector. depth, which of the following would you expect
c. Welding to be carried out on site (field weld). to be done to remove the defect?
d. The weld must be subjected to NOT. a. Arc air, ground finish and checked with crack
detection
9. Austenitic stainless steel can be readily b. Thermal gouging, ground finish and check with
identified by: MPI.
a. Lack of magnetic attraction. c. Oxy-gas cutting, ground finish and checked
b. Its extreme hardness. with crack detection.
c. Very shinny appearance. d. Both a and b.
d. None of the above. e. All of the above.

10. Which of the following is likely to be 15. The heat affected zone associated with a
considered an essential variable on a welding fusion weld:
procedure a. Usually has the highest tensile strength.
a. A change from an electrode classified to AWS b. Always exists in a fusion-welded joint.
E6011 to an electrode E6012. c. Is usually the area of a welded joint that is the
b. A change in preheat temperature from 500C to most susceptible to HICC
1500C. d. All of the above.
c. A change in welding position from PA to PF.
d. All of the above 16. Which of the following welding processes
would be the most suited for the welding of
11. Which of the following is applicable if the carbon steel in excess of 100 mm thickness
heat input is to high during the deposition of a a. Tungsten inert gas
weld made using the MMA welding process? b. Electro-slag
a. Low toughness. c. Manual metal arc.
b. High susceptibility to hydrogen entrapment. d. Plasma arc.
c. High hardness.
d. High susceptibility to lack of fusion. 17. A welding process where the welding plant
controls the travel speed and arc gap, but under a
12. Which of the following will influence the constant supervision using a shielding gas mixture
amount of distortion on a component during and of 80% argon -20% carbon dioxide is termed as:
after welding? a. A manual MAG process.
a. Heat input. b. A semi automatic MAG process.
b. Lack of restraint. c. A mechanised MIG process.
c. Material properties. d. A mechanised MAG process.
d. Both a and b.
e. All of the above. 18. The purpose of normalising steel:
a. To modify the grain structure by making it
13. When welding with the MIG welding process more uniform in order to improve mechanical
using pure argon as the shielding gas on carbon properties.

Gadamsetti
b. To soften a material for extensive machining. d. It could not be found by any testing method.
c. To reduce fracture toughness.
d. To reduce ductility. 23. Incomplete root penetration is most likely due
to:
19. Which of the following destructive tests a. Welding speed too slow.
would show the results in joules? b. Welding current too high.
a. Tensile test c. Root gap too small.
b. Charpy test. d. Electrode diameter too small.
c. Bend test.
d. Hardness test. 24. You are to oversee the arc welding of some
machined fittings and find that they are cadmium
20. Generally the most suitable method of plated. What would you do in this situation?
detecting lack of sidewall fusion on a single-V a. Permit the welding to proceed.
butt weld (30o to 35o bevel angles) would be: b. Permit the welding to proceed with fume
a. Ultrasonic testing. extraction.
b. Radiographic testing c. Stop the operation at once.
c. Magnetic particle testing d. Advise the welders to drink milk then proceed.
d. Both a and b.
e. All of the above 29. Which of the following welding process
require a drooping characteristic power source
21. Ultrasonic testing is preferable to radiographic a. TIG and MMA.
testing due to: b. MIG/MAG and MMA.
a. Ability to find all defects. c. TIG and SAW.
b. Lower amount of operator skill required d. All of the above.
c. Ability to detect laminations.
d. None of the above 30. When considering the MIG/MAG welding
process which of the following metal transfer
22. Lamellar tearing has occurred in a steel modes would be the best suited to the welding of
fabrication BEFORE welding could, thick plates over 25 mm, flat welding position.
which of the following test methods could have a. Dip transfer.
detected it? b. Pulse transfer.
a. Radiographic testing. c. Spray transfer.
b. Ultrasonic testing. d. Globular transfer.
c. Magnetic particle testing.

Gadamsetti
Key
WI-1 WI-2 WI-3 WI-4 MCQ004 & MCQ 001 MSR-AWI-1
1. a 1. 1. 1. d 1. c 41. 1. c
2. c 2. 2. 2. c 2. b 42. 2. c
3. b 3. 3. 3. b 3. c 43. 3. c
4. a 4. 4. 4. d 4. b 44. 4. c
5. c 5. 5. 5. b 5. a 45. 5. b
6. d 6. 6. 6. b 6. a 46. 6. a
7. d 7. 7. 7. d 7. b 47. 7. b
8. c 8. 8. 8. d 8. b 48. 8. c
9. b 9. 9. 9. b 9. a 49. 9. a
10. d 10. 10. 10. d 10. a 50. 10. d
11. e 11. 11. 11. a 11. b 51. 11. a
12. c 12. 12. 12. a 12. d 52. 12. e
13. a 13. 13. 13. d 13. d 53. 13. d
14. d 14. 14. 14. c 14. c 54. 14. d
15. d 15. 15. 15. d 15. c 55. 15. d
16. b 16. 16. 16. a 16. b 56. 16. b
17. c 17. 17. 17. d 17. c 57. 17. d
18. c 18. 18. 18. b 18. a 58. 18. a
19. b 19. 19. 19. b 19. c 59. 19. b
20. a 20. 20. 20. b 20. a 60. 20. a
21. d 21. 21. 21. b 21. d 61. 21. c
22. a 22. 22. 22. c 22. d 62. 22. d
23. c 23. 23. 23. d 23. b 63. 23. c
24. c 24. 24. 24. a 24. c 64. 24. c
25. c 25. 25. 25. c 25. c 65. 25. c
26. c 26. 26. 26. c 26. b 66. 26. d
27. b 27. 27. 27. e 27. c 67. 27. b
28. d 28. 28. 28. b 28. a 68. 28. b
29. d 29. 29. 29. a 29. c 69. 29. a
30. a 30. 30. 30. d 30. a 70. 30. c
31. d 71.
32. a 72.
33. b 73.
34. b 74.
35. a 75.
36. a 76.
37. b 77.
38. a 78.
39. d 79.
40. c