Master Question 2906

1.
Which of the following butt-weld preparations is usually the most susceptible

to lack of sidewall fusion during the manual metal arc process?
a. A double-U butt.
b. A single-V butt.
c. A double-V butt.
d. It is not normally a defect associated with the MMA welding process.
ANS : A : To be confirmed
2. What is the leg length of a fillet weld?

a. The distance from the toe to face.
b. The distance from the root to face centre.
c. The distance from the root to the toe.
d. Its 0.7 of the design throat thickness.
e. Both c and d
ANS: C
3. What is the throat thickness of a fillet weld (equal leg lengths)?
a. The distance from the toe to the face.
b. The distance from the root to the face centre.
c. The distance from the root to the toe.
d. The distance from toe to toe.
ANS: B
4. Compound welds:
a. Always contain butt and fillet welds
b. Joints, which have combinations of welds made by different welding
processes.
c. Combinations between two different weld types
d. All of the above.
ANS: C
5. A duty not normally undertaken by a welding inspector is to:
a. Check the condition of the parent material.
b. Check the condition of the consumables.
c. Measure residual stress.
d. Check calibration certificates.
ANS : C
6. Under most conditions, which of the following welding positions will deposit
the most weld metal.
a. PG.
b. PE.
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c. PC.
d. PA.
ANS : D
7. What meant by the term crater pipe:
a. Another term for concave root
b. Another term given for a burn through.
c. A type of gas pore, found in the weld crater.
d. A shrinkage defect, found in the weld crater.
ANS : D
8. What is meant by the term weld junction?

a. The area containing the HAZ and the weld metal.
b. The weld metal and parent metal.
c. The boundary between the fusion zone and the HAZ.
d. The part of the weld, which has undergone metallurgical changes due
to the heat from welding.
ANS: C
9. The strength of a fillet weld is primary controlled by:
a. Leg length.
b. Design throat thickness.
c. Actual throat thickness.
ANS: B
10. Which of the following is applicable for none planar defects?
a. They are always repaired.
b. Their existence will result in the removal of the entire weld.
c. They are not usually as significant as planar defects.
d. They can only be detected using radiography.
ANS: C
11. Which of the following welding processes/technique is likely to be used for the
repair welding of localised porosity in a butt weld?
a. MMA, PG position.
b. Mechanised MAG.
c. Submerged arc.
e. None of the above.
ANS : A
12. When measuring the welding parameters with the MMA welding process for
the purpose of approving a welding procedure, the Welding Inspector should
measure the voltage:
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a. As close to the welding arc as possible.
b. Anywhere along the welding cable.
c. Always from the voltmeter on the welding plant.
d. As near to the welding terminals as possible.
ANS : A
13. In the MMA welding process, which of the following is most likely to be caused
by a welder with a poor technique?
a. Deep weld craters/crater cracks.
b. Copper inclusions
c. Hydrogen cracks
ANS : A
14. Root concavity is caused by:
a. Excessive back purge pressure and entrapped gas.
b. Excessive back purge pressure and very high heat inputs.
c. Excessive root grinding and a slow travel speed.
d. Excessive root grinding and excessive back purge pressure.
ANS : D
15. When inspecting a critical component, the toes of a weld must be:
a. Always ground flush.
b. Must always overlap at least 1.5 mm onto the parent material.
c. Must always be inspected using a crack detection method (MPI, DPI).
d. None of the above can be selected – specification requirements
unknown.
ANS : D
16. When carrying out visual inspection, the specification makes no mention of
the requirements for visual inspection, in this situation what should you do?
a. Carry out normal visual inspection.
b. Seek advice from higher authority.
c. Carry out no visual inspection.
d. Re-write the requirements of the specification.
ANS : B
17. Under most circumstances, which of the following do you consider to be
duties of a welding inspector?
a. The supervision of welders.
b. Procedure writing.
c. Qualifying welders
ANS : C
18. Which of the following is most likely to cause a burn through
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a. Root gap too small.
b. Travel speed too fast.
c. Root face too small
ANS : C
19. In an arc welding process, which of the following is the correct term used for
the amount of weld metal deposited per minute?
a. Filling rate.
b. Deposition rate.
c. Weld deposition.
d. Weld duty cycle.
ANS : B
20. What is the term given for the area of a welded joint just outside the weld
metal that has undergone microstructural changes?
a. Heat affected zone.
b. The weld zone.
c. Fusion zone.
d. All of the above terms may be used.
ANS : A
21. When carrying out visual inspection, which defect (s) is likely to be missed?
a. Linear misalignment.
b. Cap undercut.
c. Porosity.
d. Lack of fusion (inter run).
ANS : D
22. Cold lapping is another term for:
a. Lack of fusion at the toe of a weld.
b. Lack of fusion between weld metal and weld metal.
c. Undercut at the toe of a weld.
d. Both a and b.
ANS : A
23. Incomplete root penetration is most likely due to:
a. Welding speed too slow.
b. Welding current too high.
c. Root gap too small.
d. Electrode diameter too small.
ANS : C
24. Crater cracks are caused mainly by:
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a. Excessively fast welding speeds
b. Improper electrode angle
c. Hot shrinkage.
d. Improper joint design.
ANS : C
25. On a single-V butt weld, the distance through the centre of the weld from root
to face is called:
a. Reinforcement.
b. Penetration.
c. Throat thickness.
d. None of the above.
ANS : C
26. The throat thickness of a ¾ inch fillet weld is?
a. 27.5 mm
b. 24 mm.
c. 13.5 mm.
d. 12.5 mm.
ANS : C
27. The need for pre-heat for steel will increase if:
a. The material thickness reduces.
b. Faster welding speeds
c. The use of a larger welding electrode
ANS : B
28. Which of the following butt weld preparations is most likely to be considered
for the welding of a 6mm thick plate?
a. Double-V butt.
b. Asymmetrical double-V butt.
c. Single-U butt.
d. Single-V butt.
ANS : D
29. A welding inspectors main attributes include:
a. Knowledge.
b. Honesty and integrity.
c. Good communicator.
ANS: D
30. A code of practice for visual inspection should cover:
a. Before, during and after welding.
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b. Before welding activities only.
c. After welding activities only.
ANS : A
1. Defects outside the permissible limits of the applicable specification should

be:
a. The decision is up to the welding inspector.
b. Repaired.
e. Always double checked using NDT.
f. All of the above.
ANS : B
2. Flux cored wires may be advantages over solid wires because:
a. Higher deposition.
b. Lower hydrogen contents in the deposited welds.
c. Easy addition of alloying elements.
d. Both a and c.
e. All of the above.
ANS : D
3. Movement of the arc by magnetic forces in an arc welding process is termed:
a. Arc deviation.
b. Arc misalignment.
c. Arc blow.
d. Stray arc.
ANS : C
4. A crack type most associated with the submerged arc welding process is:
a. Hydrogen cracking in the HAZ.
b. Solidification cracking.
c. Lamellar tearing.
d. Fatigue cracking.
ANS : B
5. Which of the following processes joins metals plastically.
a. Friction welding.
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b. Resistance welding.
c. Arc welding.
d. Plasma welding.
ANS : A
6. What type of power source characteristic is required for a manual process?
a. Constant voltage.
b. Flat characteristic.
c. Drooping characteristic.
ANS : C
7. Which of the following electrodes and current types may be used for the TIG
welding of nickel and its alloys?
a. Cerium electrode, DC –ve.
b. Zirconium electrode, AC.
c. Thorium electrode, DC +ve.
d. All of the above may be used.
ANS: A
8. What are the possible results of having a heat input to low?
a. An increase in hardness, lower yield strength and lack of fusion.
b. A reduction in toughness, hydrogen entrapment and an increase in
hardness.
c. Entrapped hydrogen, an increase in hardness and lack of fusion
d. Entrapped hydrogen, a reduction in carbon content and lack of fusion.
ANS : C
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9. The main reason for using a back purge when welding 18-8 stainless steel
with the TIG welding process is to:
a. Improve positional welding.
b. Prevent the possibility of porosity.
c. Prevent excessive root penetration
d. Prevent the formation of a dense oxide layer forming in the root.
ANS : D
10. The possible effects of having a travel speed too fast:

a. Low toughness, slag inclusions and cap undercut.
b. High hardness, slag inclusions and a narrow thin weld bead.
c. High hardness, excessive deposition and cold laps
d. Low toughness, poor fusion and slag inclusions.
ANS : B
11. If arc blow exists when welding with the MMA welding process, this can be
best reduced or eliminated by:
a. A change from AC to DC current.
b. A change from DC to AC current.
c. A change from DC +ve to DC –ve.
d. A change from DC –ve to DC +ve.
ANS : B
12. When welding a double-V butt weld with the submerged arc welding process
the presence of centre line porosity may be due to:
a. Damp flux.
b. Contamination on the weld preparations.
c. Incorrect flux depth
ANS : D
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13. The inclusion of an inductance in the welding circuit when using MIG/MAG
welding process is to:
a. Control the rate of spatter in the dip transfer mode.
b. It enables the welder to weld in position with the spray transfer mode.
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.
ANS : A
14. An undesirable property of aluminium oxide residue, when welding is that it:
a. Decrease weld pool fluidity.
b. Requires more heat to melt it when compared to aluminium.
c. Causes the welder to travel to quickly.
d. The presence of the oxide makes aluminium impossible to weld.
ANS : B
15. When welding with the MIG welding process using pure argon as the
shielding gas on carbon steel, which of the following problems are likely to occur?
a. Copper inclusions and excessive cap heights.
b. Excessive root penetration and porosity.
c. Slag inclusions and crater pipe.
d. Lack of fusion and poor cap profiles.
ANS : D
16. When considering the tungsten arc welding process what is the purpose of
the down-slope (slope-out) control?
a. Ensure good penetration.
b. To prevent arc striking on the parent material.
c. To help prevent the formation of crater pipe and possible cracking.
d. To help prevent tungsten inclusions during welding.
ANS : C
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17. When considering thermal cutting local hardening can be reduced by:
a. Increasing the cutting speed.
b. The use of propane as a fuel gas.
c. Pre heating the material to be cut.
ANS : C
18. In a semi-automatic welding process, which of the following shielding gas/gas
mixtures would normally give the deepest penetration on steel?
a. 100% argon.
b. 100% CO2.
c. 75% argon + 25% CO2.
d. All of the above would give the same depth in penetration.
ANS : B
19. In a MMA welding process, which of the following statements are false?
a. An arc gap, which remains almost constant even if as usual the welder
varies the position of the electrode.
b. A voltage, which remains almost constant even if as usual the welder,
varies the arc gap.
c. A current, which remains almost constant even if as usual the welder,
varies the arc gap.
d. A and b.
ANS : D
20. When considering the MIG/MAG welding process which of the following metal
transfer modes would be the best suited to the welding of thick plates over 25
mm, flat welding position.
a. Dip transfer.
b. Pulse transfer.
c. Spray transfer.
d. Globular transfer.
.
ANS :C
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21. Which of the following current types would you expect to be used for the
welding of aluminium with the TIG welding process?
a. DC -ve.
b. DC +ve.
c. AC
ANS : C
22. Which of the following statements is false?
a. In the MMA welding process electrode DC + produces a deep narrow
weld pool, which is fast freezing.
b. DC electrode positive is used for the MAG welding of steel plate.
c. In the MAG welding process the wire feed speed remains constant
during the welding operation
d. All of the above
ANS : A
23. When considering hydrogen, which of the following welding process would
produce the lowest levels in the completed weld (under controlled conditions)
a. MMA.
b. SAW.
c. TIG.
d. FCAW.
ANS : C
24. Pre heat prior to the welding of a carbon steel butt weld:
a. Must always be carried out.
b. Is always carried out using a gas flame
c. Need not be carried out if post weld heat treatment is to follow
ANS : D
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25. In steel the element with the greatest effect on hardness is:
a. Chromium.
b. Manganese.
c. Carbon.
d. Nickel.
ANS : C
26. For a given voltage and current settings on a MMA welding plant, when the
arc length is shortened, which of the following will be most affected.
a. The current will increase.
b. The current will decrease.
c. The voltage will decrease.
d. The voltage will increase.
ANS: C
27. Which of the following best describes a semi-automatic welding process?
a. The welder is responsible for the maintaining the arc gap and travel
speed.
b. The welder is responsible for travel speed only; arc gap is kept
constant by the welding plant.
c. Both travel speed and arc gap is controlled by the welding plant
ANS : B
28. What is purpose of a rectifier in a welding sets electrical circuit?
a. To keep the arc stable when using low current settings
b. To convert AC current to DC current.
c. To convert DC current to AC current.
d. To initiate the arc at start up.
ANS : B
29. When calibrating a mechanised MAG welding plant, which of the following
applies (WFS = Wire feed speed)?
a. Check – WFS, current, volts and wire diameter.
b. Check – WFS, joint set-up, gas flow rate and WFS.
c. Check – Gas flow rate, stick out length, WFS and current.
ANS : C
30. The main usage of the arc air process is:
a. The cutting of a weld preparation.
b. The removal of defective welds.
c. For the cutting of non-ferrous materials only.
d. For the cutting of ferrous materials only.
ANS : B
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Welding Inspection, Steels – WIS 5
Multi – Choice Question Paper (MSR-WI-3)
Name: ……………………………………………….
Answer all questions
1. The likelihood of a brittle fracture in steels will increase with:

a. The formation of a fine grain structure.
b. A reduction in-service temperature to sub-zero conditions.
g. A slow cooling rate.
h. All of the above.
ANS : B
2. Hydrogen cracking in HAZ is most likely to occur when welding:
a. Carbon manganese steels.
b. Austenitic stainless steel.
c. Micro alloyed steel (HSLA).
d. Low carbon steel.
ANS : A
3. Which of the following are considerations for the selection of a preheat
temperature:
a. Carbon equivalent, joint design, welding process type and plate
material quality.
b. All Joints over 25 mm thick, hydrogen levels, welding process, carbon
equivalent.
c. Arc energy, material thickness, hydrogen scale and carbon equivalent.
d. All of the above are considerations for the selection of a preheat
temperature.
ANS : C
4. Which of the following destructive tests would indicate the toughness value of
the weld metal/parent metal and HAZ?
a. Macro.
b. Nick break.
c. Tensile.
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d. Charpy Vee notch.
ANS : D
5. What constituent is needed in a coating of an electrode to prevent the
formation of porosity when welding rimming steel?
a. Iron powder.
b. Potassium silicate.
c. Silicon
d. Calcium carbonate.
ANS : C
6. Welds made with high heat inputs show a reduction in one of the following
properties?
a. Ductility.
b. Toughness.
c. Elongation.
d. Penetration.
ANS : B
7. Which of the following steel types would give rise to the formation of porosity
when autogenously welded with an arc welding process
a. Fully killed steel.
b. Semi killed steel.
c. Rimming steel.
d. Balanced steel.
ANS : C
8. Which of the following elements, which may be added to steel, has the
greatest affect on creep strength.
a. Tungsten.
b. Manganese.
c. Carbon.
d. Molybdenum.
ANS : D
9. The HAZ associated with a fusion weld:
a. Can not be avoided.
b. Usually has the highest tensile strength.
c. Is usually martensitic.
d. Both a and b.
ANS : D
10. What four criteria are necessary to produce hydrogen induced cold cracking?
a. Hydrogen, moisture, martensitic grain structure and heat.
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b. Hydrogen, poor weld profiles, temperatures above 200oC and a slow
cooling rate.
c. Hydrogen, a grain structure susceptible to cracking, stress and a
temperature below 200oC.
d. Hydrogen, existing weld defects, stress and a grain structure
susceptible to cracking.
ANS: C
11. A carbon equivalent (CE) of 0.5%:
a. Is high for carbon manganese steel and may require a preheat over
100oC
b. Is generally significant for carbon for manganese steels and is certainly
not to be taken into consideration for preheat temperatures.
c. Is high for carbon manganese steels and may require a preheat
temperature over 300oC as to avoid cracking
d. Is calculated from the heat input formula.
ANS : A
12. In a martensitic grain structure what would you expect to increase?
a. Ductility.
b. Hardness.
c. Toughness.
ANS : B
13. In which of the following mechanical tests would you expect to use a
comparison from ductile to brittle transition curve.
a. Tensile test.
b. Charpy test.
c. Fusion zone test.
d. All of the above
ANS : B
14. Which of the following heat treatments on steel cools down in air from the
austenite region?
a. Normalising.
b. Annealing.
c. Tempering.
d. Stress relieving.
AND: A
15. What is the purpose of microscopic examination of a weld?
a. To determine the number and type of defects present.
b. To determine the grain size.
c. To determine the strength of the weld.
d. Both a and b.
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ANS: D
16. Which of the following units is a tensile specimen usually measured in?
a. Pounds per square inch.
b. Newton per square inches.
c. Joules.
d. Both a and b.
ANS : A
17. Assuming that the welding process, material thickness, carbon equivalent and
the welding parameters to be the same, which of the following joint types
would normally require the highest preheat temperature.
a. Edge joint.
b. Lap joint.
c. Butt joint (single-V).
d. Tee joint (fillet welded).
ANS: D
18. Austenitic stainless steels are more susceptible to distortion when compared
to ferritic steels this is because:
a. High coefficient, low thermal conductivity.
b. High coefficient, high thermal conductivity.
c. Low coefficient, high thermal conductivity.
d. Low coefficient, low thermal conductivity,
ANS : A
19. Which of the following will most likely require the preheat temperature to be
increased?
a. An Increase in travel speed.
b. A reduction in material thickness
c. An increase in electrode diameter.
ANS : A
20. Which of the following properties may be applicable to a carbon steel weld
(CE 0.48) welded without preheat?
a. Narrow heat affected zone and hardness value in excess of 400 HV.
b. Broad heat affected zone and hardness values in excess of 400 HV.
c. A very tough and narrow heat affected zone.
d. Narrow heat affected zone and low hardness values.
ANS : A
21. Which of the following materials is considered to be the easiest to weld?
a. Mild steel.
b. Medium carbon steels.
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c. Martensitic stainless steel
d. Forging steel.
ANS : A
22. Which of the following test pieces taken from a charpy test on a carbon-
manganese steel weld, welded with a high heat input is most likely to have the
lowest toughness
a. Test piece taken from parent metal.
b. Test piece taken from weld metal.
c. Test piece taken from HAZ.
d. All of the above values will be the same.
ANS : C
23. Which of the following butt weld preparations would normally be considered
for a mechanised welding process
a. Single-V butt, root gap 2.5 mm (welded from on side only).
b. Double-V butt-welded both sides, root gap 2.0 mm.
c. Single-U butt with backing.
d. None of the above can be used for mechanised welding.
ANS : C
24. Which is the correct heat input for the following parameters, amps 350, volts
32 and the travel speed 310 mm/minute (MMA welding process)?
a. 2.16 kJ/mm.
b. 0.036 kJ/mm.
c. 2160 kJ/mm.
d. 3.6 kJ/mm.
ANS : A
25. Assuming that the applicable specification makes no mention of arc strikes,
what would you expect to do as a welding inspector if arc strikes were found
on a component made of a high tensile strength material.
a. Have the welder re-qualified.
b. Ignore them.
c. Have the area checked for possible cracking.
d. Cut out the entire weld where the arc strikes exist.
ANS: C
26. A multi-pass MMA butt weld made on carbon steel consists of 5 passes
deposited using a 6mm diameter electrode. A 12-pass weld made on the
same joint deposited using a 4mm diameter electrode on the same material
will have:
a. A lower heat input and a higher degree of grain refinement.
b. A lower heat input and a coarse grain structure.
c. A lower amount of distortion and a higher degree of grain refinement.
d. A higher amount of distortion and a lower degree of grain refinement.
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ANS : A
27. What is the purpose of a transverse tensile test?
a. To measure ultimate tensile strength.
b. To measure the elongation of a material
c. To measure the yield strength of a material
ANS : D
28. Which of the following mechanical tests can be used to give a quantitative
measurement of weld zone ductility?
a. Tensile test.
b. Bend test.
c. Charpy V notch test.
ANS : A
29. Which of the following are reasons for applying preheat?
a. The removal of residual stress.
b. To aid slow cooling and reduce the carbon content.
c. To reduce the chance of a brittle grain structure and to reduce the
chance of hydrogen entrapment.
d. Increase the ultimate tensile strength values and increase overall
weldability.
ANS : C
30. Which of the following are true with regards to a charpy test.
a. It’s a static test used to determine a materials notch toughness in the
weld region.
b. It’s a dynamic test used to determine a materials notch toughness in
the weld region.
c. It’s a destructive test to give a measurement of through thickness
ductility.
ANS : B
Multi – Choice Question Paper (MSR-WI-4)
Name: ……………………………………………….
1. Degreasing components are essential for quality welding but when welded
some agent may:
a. Cause corrosion problems.
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b. Leave residues
c. Give off toxic gases.
ANS : D
2. Cellulose electrodes are often used for the deposition of a root pass on pipes
welded in the field. This is because?
a. Hydrogen control is required.
b. The high deposition rate due to the iron powder content.
c. The hydrogen gas produced in the flux increases the arc voltage.
ANS : C
3. In the welding of austenitic stainless steels, the electrode and plate materials
are often specified to be low carbon content. The reason for this:
a. To prevent the formation of cracks in the HAZ.
b. To prevent the formation of chromium carbides
c. To prevent cracking in the weld.
d. Minimise distortion.
ANS : B
4. With regards to a welding procedure, an essential variable may:
a. Change the properties of the weld.
b. Influence the visual acceptance.
c. Require re-approval of a weld procedure.
d. All of the above
ANS : D
5. Which of the following NDT methods can only detect surface breaking
defects?
a. MPI
b. DPI.
c. UT
d. RT.
e. Both a and b.
ANS : B
6. Which of the following defects would show up as light indications on a
radiograph?
a. Slag inclusions and copper inclusion.
b. Tungsten inclusions and excessive root penetration.
c. Cap undercut and root piping.
d. Excessive cap height and incomplete root penetration
ANS : B
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7. Which of the following additions may be added to an electrodes flux to act as
a stabilizer?
a. Sodium silicate
b. Silicon
c. Manganese
d. Titanium dioxide.
ANS: D
8. Lamellar tearing is best prevented by:
a. The use of plate materials containing low levels of impurities.
b. The use of buttering runs.
c. Post weld stress relief.
d. Both a and b.
ANS : D
9. When considering radiography using X-ray, which of the following techniques
is most likely to be used for a pipe to pipe weld (circumferential seam),
610mm diameter with no internal access?
a. SWSI.
b. DWSI.
c. DWDI.
d. SWSI-panoramic.
ANS : B
10. A balanced welding technique for example back step welding is most often
used for:
a. Controlling lamellar tearing.
b. Increasing weld toughness.
c. Reducing weld zone hardness.
d. Reducing distortion.
ANS : D
11. Basic coated electrodes have which of the following properties.
a. High mechanical properties may be used to produce welds of high
deposition rates and to produce welds of low hydrogen content.
b. Friable slag, high mechanical strength, and to produce welds of a low
hydrogen content.
c. Low hydrogen content welds, good stop/start properties and high
strength.
d. Low carbon content welds, friable slag and high strength.
ANS : A
12. On a radiograph, the most likely appearance of lack of root fusion on a single-
V butt weld is:
a. A dark straight line with a light root.
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b. A dark root with straight edges.
c. A dark uneven line following the edge of the root
d. None of the above lack of root fusion can not be seen on a radiograph.
ANS : A
13. Which of the following applies to the heat treatment process of tempering
a. It is always carried out at a temperature above upper critical limit.
b. It is carried out to increase the strength and toughness of weldments.
c. Tempering is generally carried out before quench hardening.
d. None of the above
ANS: D
14. Which of the following is applicable to a plate lamination
a. They are best detected by radiography.
b. They are mainly caused by hydrogen entrapment.
c. They originate in the parent material.
d. They are caused when welding stresses act parallel with the rolled
direction of the parent plate.
ANS : C
15. Which of the following NDT methods would be the least effective on an
austenitic stainless steel butt weld.
a. UT.
b. RT.
c. DPI.
d. MPI.
ANS: D
16. The hardest part of a multi-pass welded joint, assuming no post weld heat
treatment has have taken place is:
a. The HAZ of the cap.
b. The HAZ of the root.
c. The root.
d. The cap.
ANS : A
17. Is it permissible to allow a multi-pass butt weld to cool down between weld
passes?
a. It should be up to the welding inspector.
b. No the weld must be kept hot at all times.
c. It depends on the welder
d. It depends on the specification requirements.
ANS : D
18. A tee joint on a support bracket is to be welded both sides using a 5 mm leg
length fillet weld, each weld is to be intermittent 50 mm in total length, the gap
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5 5 x 50 (25)
5 50 (25)
a. b.
between each weld is to be 25 mm. Which of the following is the correct
symbol in accordance with ISO 2553?
ANS : B
19. The usual method of assessing the sensitivity and density of a radiograph is
by means of:
a. Densitometer and dosimeter.
b. Penetrameter and a densitometer.
c. IQI and a dosimeter.
d. IQI and a fluxmeter.
ANS : B
20. In the submerged arc welding process, the use of excessive high voltages
would result in?
a. Insufficient flux melting.
b. Excessive flux melting
c. Slag removal difficulties.
d. Excessive spatter.
ANS: B
21. Welding a steel plate with a CE of 0.45 would require preheating to?
a. Prevent the formation of sulphides.
b. Prevent hardening in the HAZ.
c. Prevent the formation of carbides.
d. To reduce the amount of current required.
ANS: B
22. Which of the following welding process uses a resistive heating system to
achieve weld metal deposition?
a. MMA
b. Resistant spot welding.
c. Electro-slag.
d. Friction welding.
ANS : C
23. What does the 70 represent on an E70 10 AWS A5.1 classified electrode?
a. 70 N/mm2 minimum UTS.
b. 70 joules minimum impact strength.
c. 70,000 p.s.i. Minimum yield strength.
d. 70,000 psi minimum UTS.
ANS: D
24. Hot cracking in steel weldments occurs:
a. Along the fusion line.
b. In the last metal to solidify.
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c. Weld centre line
d. In areas of the lowest dilution.
ANS : B
25. Cellulose electrodes have which of the following properties?
a. Viscous slag, large volumes of shielding gas and UTS values above
90,000 psi.
b. Large volumes of shielding gas, high spatter contents and hydrogen levels
< 15 ml per 100g of weld metal deposited
c. Large volumes of shielding gas, hydrogen contents > 15 ml per 100g of
weld metal deposited and should be never baked.
d. High spatter contents, high deposition and large volumes of gas shield.
ANS: C
26. From the following electrode coding in BS EN 499, E50 3 1Ni B 140 0 1 H5 ,
what does the 3 represent
a. A minimum charpy value of a 30 joules.
b. A minimum impact value of 47 Joules.
c. A minimum impact temperature of –30oC at a given Joule value.
ANS: C
27. Which of the following is applicable to electrode efficiency?
a. The mass of metal deposited as a percentage of the mass of core wire
melted.
b. Iron powder electrodes have efficiencies above 100%.
c. Electrodes of high efficiencies tend to produce welds of a smooth flat
profile.
d. Both a and b.
ANS : D
28. A Fatigue cracks fracture surface is:
a. Rough randomly torn.
b. Smooth.
c. Step like appearance.
d. Bright crystalline.
ANS : B
29. E6013 electrode would most probably used for welding:
a. Low pressure pipework.
b. High-pressure pipework.
c. Vertical down welding on storage tanks.
d. In a situation where low hydrogen welds are specified.
ANS: A
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30. Which element in steel if present in significant amounts may lead to hot
shortness?
a. Phosphorus.
b. Manganese.
c. Silicon.
d. Sulphur.
ANS : D
Assessment Question Paper (MSR-AWI-1 05)
Name: ……………………………………………….
1. What is the Arc energy for the following welding process parameters?
Amps 140, Volts 21, Travel speed 250mm/min.
a. 0.7 KJ/mm
b. 0.6 KJ/mm
c. 0.01 KJ/mm
d. 0.7 J/mm
ANS: A
2. What is the effect of tempering after quenching
a. Toughness and strength are increased.
b. Toughness and strength are reduced.
c. Toughness reduced and strength increased
d. Toughness increased and strength reduced
e. Toughness increased and hardness increased
ANS :C
3. What is the ratio between the leg length and the design throat thickness on a mitre
fillet weld with equal leg lengths
a. 1 to 1
b. 2 to 1.
c. 1.414 to 1.
d. All of the above it depends upon the leg length size.
ANS: C
4. The toughness and yield strength of steel is reduced by:
a. Reducing the grain size
b. Increasing the heat input.
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c. Reducing the heat input.
d. Both a and b.
ANS : B
5. Which of the following statements is true if applicable to a charpy vee notch impact
test
a. It’s a destructive test used to assess materials ductility in the weld zone.
b. It’s a mechanical test used to determine a welds resistance to creep.
c. It’s a dynamic test, which is used to give a measure of notch toughness.
d. It’s a static test used to determine materials toughness in the notch region.
e. Both a and c.
ANS: C
6. How can you tell the difference between an EN/ISO weld symbol and a BS weld
symbol?
a. The EN/ISO weld symbol will always have the arrow side weld at the top of the
reference line.
b. The EN/ISO symbol has the welds elementary symbol placed on a dashed line
lying above or below the solid reference line to indicate a weld on the other side.
c. The EN/ISO symbol has a fillet weld leg length identified by the letter “a”.
d. The EN/ISO symbol has a fillet weld throat thickness identified by the letter “z”.
e. Both b and d.
ANS :B
7. What is the possible effect of having the heat input too low during welding?
a. Low toughness, entrapped hydrogen and low hardness.
b. High hardness, lack of fusion and entrapped hydrogen.
c. Entrapped hydrogen, low toughness and high ductility.
d. Lack of fusion, low toughness and a reduction in ductility.
ANS : B
8. An MMA electrode classified as E7018 is:
a. A basic low hydrogen electrode containing iron powder.
b. A rutile electrode containing iron powder.
c. A cellulose electrode suitable for welding in all positions.
d. A basic electrode depositing weld metal with yield strength of a least 70,000 psi.
e. both a and d.
ANS: A
9. The number 135 is placed at the end of the reference line on a weld symbol.
According to ISO 2553 what does this number indicate?
a. The welding process is stated as MMA
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b. The welding process is stated as TIG
c. The welding process is stated as SAW
d. NDT is to be carried out after welding
e. None of the above
ANS : E
10. Which of the following is the most likely to be considered an essential variable for a
welder qualification test?
a. A change from an electrode classified to BS EN 499 as an E46 3 INI B to an
electrode classified to AWS A5.1 as an E7018.
b. A change of pipe wall thickness by at least 15 mm.
c. A change in pre-heat temperature from 50oC to 100oC.
d. A change from PC welding position to PA welding position.
ANS : B
11 What would be a typical appearance of a ductile fracture surface?
a. Rough randomly torn and a reduction in area.
b. Smooth fracture surface displaying beach marks
c. Step like appearance.
d. Bright crystalline fracture with very little reduction in area.
e. Both a and b.
ANS: A
12. In EN 499, what does the number 50 represent in the following electrode
classification?
E 50 3 1Ni B 160 0 1 H5.
a. A minimum of 50 N/mm2 yield strength
b. A minimum of 500 N/mm2 tensile strength
c. A minimum of 50000 psi yield strength
d. A minimum of 50000 psi tensile strength
e. None of the above.
ANS : A
13. Increasing the carbon content of a steel will:
a. Increase the hardness and toughness
b. Decrease the hardness and toughness
c. Increase hardness, decrease toughness
d. Decrease hardness, increase toughness
ANS: C
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14. Which of the following is applicable for the HAZ on a C/Mn steel weld if the heat
input increases:
a. Both hardness and width is increased.
b. Hardness decreases, width increases.
c. Both hardness and width decreases.
d. Hardness increases, width decreases.
ANS : B
15. What is the main reason for the application of pre-heat
a. To change the chemical composition of the weld and parent material.
b. The control the hydrogen and prevent cracking.
c. To remove residual stresses.
d. Both a and b.
e. All of the above
ANS : B
16. Which of the following is most likely to increase the chance of solidification cracking?
a. Reduction in sulphur content of the parent material
b. Increased restraint on the joint during welding.
c. Increase in weld hydrogen content from 15 ml/100 g to 25 m/l100 g.
d. Poor through thickness ductility in the materials being welded.
e. Both a and b.
ANS : B
17. What is the effect of full annealing compared to normalizing?
a. A reduction in grain size.
b. An increase in grain size.
c. An increase in toughness
d. The grain size will not be affected.
e. None of the above
ANS: B
18. Which of the following elements may cause cold shortness (brittleness)
a. Sulphur.
b. Phosphorous
c. Manganese.
d. Silicon
ANS :B
19. When considering the advantages of site radiography over ultrasonic inspection
which of the following applies?
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a. A permanent record produced good for detecting lack of sidewall fusion in a
single U butt weld and defect identification.
b. A permanent record produced, good for the detection of all surface and sub-
surface defects and assessing the through thickness depths of defects.
c. Permanent record produced, good for defect identification and not as reliant upon
surface preparation.
d. No controlled areas required on site, a permanent record produced and good for
assessing pipe wall thickness reductions due to internal corrosion.
e. Both a and c
ANS: C
20. Which of the following materials are the most susceptible to HICC in the weld zone
a. Carbon Manganese steel
b. Micro alloyed steel (HSLA).
c. Austenitic steel
d. Both a and b
e. All of the above
ANS: D
21. Lamellar tearing is:
a. A product defect caused during the manufacturing of certain steels
b. A crack type, which occurs in the parent material due to welding strains acting in
the short transverse direction of the parent material.
c. A type of hot crack associated with impurities (sulphur, carbon and
phosphorous).
d. A type of crack that occurs in the weld or parent material due to cyclic stresses.
ANS: B
22. Which of the following statement maybe considered correct when dealing with
agglomerated fluxes?
1. Easy addition of additive

2. They’re less hygroscopic than other types
3. Flaky appearance
4. Need to bake, prior to their use
5. Less dust tendency
A. Statements 1 & 4 are correct

B. Answer 1 and 3 are correct
C. Answer 4 and 5 are correct
D. Statements 1, 2,4 and 5 are correct
ANS: B
23. Which of the following is applicable to the heat treatment process of normalising
carbon-manganese steel
a. It is always carried out below the lower critical limit.
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b. It is carried out to ensure the material has maximum tensile strength.
c. It is carried out to ensure the material is of maximum ductility and malleability in
preparation for extensive cold working operations.
d. It is carried out at approximately 910oC for the purpose of grain refinement
ANS : D
24.A tee joint on a support bracket is to be welded both sides using 5 mm leg length
fillet welds, each weld is to be intermittent 50 mm in length, and the gap between
each weld is to be 25 mm. In accordance with EN 22553 which of the following
a. c.
5 50 (25) 5 x 50 (25)
5 50 (25) 5 x 50 (25)
symbols gives the correct representation?
25 (50) 5 x 50 (25)
5 25 (50) 5 x 50 (25)
b. 5 d.
ANS : A
25. Austenitic stainless steel can be identified by:

a. Very shiny appearance.
b. Lack of magnetic attraction.
c. Its extreme hardness.
d. None of the above
ANS: B
26. Ultrasonic testing is preferable to radiographic testing due to:
a. Its ability to detect all defects.
b. Lower amount of operator skill required.
c. Its ability to detect laminations.
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d. Its ability to detect both sub-surface and surface defects in Austenitic stainless
steel.
ANS : C
27. Which of the following flame types would you expect to be used for the cutting of
mild steel?
a. Carburising flame.
b. Oxidising flame.
c. Reducing flame.
d. Neutral flame.
ANS : D
28. The heat affected zone of a carbon steel fusion weld
a. Usually has the highest tensile strength and highest toughness values
b. Usually has the lowest toughness values and cannot be avoided
c. Is usually gamma iron phase and cannot be avoided
d. Both a and c.
ANS: B
29. A welding process where the welding plant controls the travel speed and the arc
gap, but under constant supervision using a shielding gas mixture of 80% argon –
20% carbon dioxide is termed:
a. A manual MAG process.
b. A semi-automatic MAG process.
c. A mechanised MIG process.
d. A mechanised MAG process.
ANS : D
30. The main reason for toe blending on certain welded components is:
a. Corrosion considerations.
b. Fatigue life.
c. Appearance.
d. All of the above
ANS: B
01. When “H2 control” is specified for a manual metal arc welding project, the
electrode would normally be:
(a) Cellulose
(b) Iron oxide
(c) Acid
(d) Basic
ANS : D
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02. You would with certainty recognize a hydrogen controlled flux covered electrode
from its:
(a) Colour
(b) Length
(c) Trade Name
(d) AWS / BS639 Code Letter
ANS : D
03. When manual metal arc welding is being carried out on an open construction site,
which group of welders are the most likely to require continuous monitoring?
(a) Concrete shuttering welding teams
(b) Pipe welding team
(c) Plater welders
(d) Plant maintenance welders
ANS : B
04. You notice manual metal arc electrodes, stripped of flux, are being used as filler
wire for TIG welding. You would object because:
(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
ANS :C
05. When open site working, serious porosity in metal arc welds is brought to your
attention. What would you investigate:
(a) Electrode type
(b) Power plant type
(c) Electrode storage
(d) Day temperature
ANS : C
06. The steel composition in a structural contract is changed form 0.15% carbon, 0.6%
manganese to 0.2% carbon, 1.2% manganese. Might this influence the incidence of:
(a) Porosity
(b) Cracking in the weld area
(c) Undercut for fillet welds
(d) Lack of root fusion defects
ANS : B
07. One of the following alloys is non-magnetic. Which?
(a) 4% Chromium Molybdenum
(b) 12% Chromium
(c) Austenitic Stainless Steel
(d) 9% Nickle Steel
ANS : C
08. When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is called for.
This is to:
(a) Prevent oxidation
(b) Prevent under bead cracking
(c) Prevent porosity
(d) Control the penetration bead shape
ANS : A
09. Pre-heating a carbon steel manual metal arc welding is carried out to minimize the
risk of:
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(a) Scattered porosity
(b) Worm hole porosity
(c) Parent metal cracking
(d) Lack of penetration
ANS : C
10. In UK practice, BS499 part 2 specifies that the drawing dimension quoted for a
fillet weld is the:
(a) Leg length
(b) Actual throat thickness
(c) Weld length
ANS : A
11. For open site manual metal arc welding the following equipment is available.
Which would you choose for safe working?
(a) Single operator transformer
(b) Multi operator transformer
(c) AC / DC composite power unit
(d) Diesel engine driven motor generator
ANS : D
12. If Submerged arc welding is to be used to make butt welds, which would you be
most critical of?
(a) The root gap tolerance
(b) The angle of preparation
(c) The root face width
(d) The gas cut finish
ANS : A
13. During CO2 welding, the arc length is most likely to be affected by:
(a) The wire diameter
(b) The current return connection
(c) The gas flow rate
(d) The torch to work angle
ANS : D
14. Preheating for arc welding applies to:
(a) Assembly welding only
(b) Assembly and tack welding
(c) Joints over 25mm thick only
(d) Cruciform welds only
ANS : B
15. You see a welder using an oxy-acetylene flame with a long feathered inner cone.
What would be the effect of this on a carbon steel?
(a) The weld could be hard and brittle
(b) The weld metal could be too soft
(c) There will be no effect on the weld
(d) The weld will have undercut
ANS : A
16. A welder qualification test is to verify:
(a) Skill of the welder
(b) The quality of the materials
(c) The non-destructive test procedures
(d) The manufacturing method
ANS : A
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17. A fabricating procedure calls for fillet welds to be “blended in” by grinding. This is
to influence:
(a) H A Z cracking
(b) Fatigue life
(c) Residual stress
(d) Yield strength
ANS : B
18. Bend test specimens have been taken from a 25mm thick carbon steel butt weld.
Which would show lack of inter-run fusion:
(a) Side bend
(b) Root bend
(c) Face bend
(d) Guided bend
ANS : A
19. Lamellar tearing has occurred in a steel fabrication. Before welding could it have
been found by:
(a) X-ray examination
(b) Dye penetrant
(c) Ultrasonic inspection
(d) It would not have been found by any inspection method
ANS : D
20. You are to oversee the arc welding of some machined fittings and find they are
cadmium plated. Would you:
(a) Permit it to proceed
(b) Permit it to proceed with fume extraction
(c) Stop the operation at once
(d) Advise the welder to drink milk and proceed
ANS : C
21. The unit of Joules would be used to measure:
(a) Tensile strength
(b) Impact energy
(c) Hardness
(d) Electrical resistance
ANS : C
22. Submerged arc welding is a process that generally gives:
(a) Slag free welds
(b) Low penetration
(c) Low dilution
(d) High heat input
ANS : D
23. Which of the following does not require baking or drying:
(a) E 6010
(b) E 7018
(c) Sub are flux with Basicity Index of 2
(d) Sub are flux with Basicity Index of 3
ANS : A
24. A welder and procedure re-qualification would be required:
(a) When the run out date of the procedure has been reached
(b) Every Year
(c) When changing from day to night shift work
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(d) When there is a change in an essential variable
ANS : D
25. Tensile strength can be increased in steel by:
(a) Annealing
(b) Galvanising
(c) Addition of carbon
(d) Casting
ANS : C
26. Which of the following always occurs in the parent material:
(a) Hydrogen cracks
(b) Laps and laminations
(c) Center line cracks
(d) Porosity
ANS : B
27. To prevent the hardening and cracking of High Carbon Steel plate when flame
cutting it is advisable to:
(a) Pre-heat the plate
(b) Soak the plate in oil
(c) Cool the plate quickly after cutting
(d) Increase the cutting Oxygen pressure
ANS : A
28. Re-crystallization during annealing is used to make steel:
(a) Softer
(b) Harder
(c) Tougher
(d) Stronger
ANS: D
29. You should always refer to a higher authority for guidance when:
(a) Cracks appear during welding
(b) The welder will not follow your instructions
(c) Instructions are missing in the specification or contract documents
(d) All of the above
ANS : D
30. Spatter may be finely controlled during MIG / MAG welding by:
(a) Adjusting the inductance control
(b) Using CO2 gas
(c) Increasing the arc voltage
(d) Welding with no gas
ANS : A
31. Fatigue testing is used to test welds:
(a) Under cyclic loading
(b) Under creep stress loading
(c) Under impact loading
(d) Under static loading
ANS : A
32. Argon + 2% Oxygen is used when welding:
(a) High carbon steels
(b) Austenitic stainless steels
(c) Aluminum
(d) Martensite stainless steels
34 0f 9
ANS: B
33. In BS 639 and BSEn 499 the first digits of the electrode classification indicate:
(a) Tensile and yield strength
(b) Toughness
(c) Electrode coating
(d) Electrode efficiency
ANS : A
34. Cellulosic coatings are generally used because of:
(a) Their low hydrogen content
(b) Their high penetration characteristic
(c) Their high strength weld deposit
(d) Their high weld toughness values
ANS : B
35. Porosity would mostly occur in which of the following:
(a) When MMA welding semi de-oxidized steel
(b) When MIG / MAG welding fully de-oxidized steel
(c) When welding TIG welding non de-oxidized steel
(d) When Sub Arc Welding semi killed steel
ANS : A
36. When welds have a depth to width ration of higher than 2:1 it is possible that:
(a) Centerline cracks may appear
(b) The fusion boundary will be outside the HAZ
(c) The HAZ will be too narrow
(d) The weld will be non magnetic
ANS: A
37. On which of the following would you not use MPI inspection?
(a) A low carbon steel butt welded joint
(b) An Austenitic Stainless steel fillet welded T joint
(c) A medium carbon steel fillet welded lap joint
ANS : B
38. Increasing the arc energy input of a welded joint will:
(a) Increase the strength of the joint
(b) Increase the toughness of the joint
(c) Increase the grain size of the weld and HAZ
(d) Decrease the width of the HAZ
ANS : C
39. In Sub Arc Welding, excessive flux melting will result from:
(a) Increasing the arc voltage
(b) Decreasing the arc voltage
(c) Increasing the travel speed
(d) Increasing the wire feed speed
ANS : A
40. To BS 499 part 2, which of the following is true for a welding symbol:
(a) This or arrow side of the joint goes on top of the reference line
(b) This or arrow side of the joint goes below the reference line
(c) This or arrow side of the joint goes in the middle of the reference line
ANS : B
41. Internal lack of fusion defects can be normally found by using:
35 0f 9
(a) Penetrant testing
(b) Impact tests
(c) Side bend test
(d) Hardness test
ANS : C
42. Which of the following steel structures has the highest hardness:
(a) Martensite
(b) Austenitic
(c) Ferritic
(d) All have the same hardness
ANS : A
43. An IQI would be used in radiography to assess:
(a) Image quality
(b) Type of steel
(c) Density of graph
(d) Type of welding process used
ANS : A
44. Poor penetration would be found in MIG / MAG welded steels when using:
(a) Argon + 20% CO2
(b) CO2
(c) Pure Argon
(d) Argon + 5% CO2
ANS : C
45. In which of the following steels are you most likely to find H2 induced weld metal
cracking after welding:
(a) Low carbon steel
(b) High strength low alloy steel
(c) Austenitic stainless steels
(d) 1% Nickel steel
ANS: B
46. Silicon is added to electrode coating as:
(a) A slipping agent
(b) A slag former
(c) A de-oxidant
(d) A colouring agent
ANS : A
47. The main reason degreasing agents should always be dried from metals prior to
welding, is because they are likely to:
(a) Increase the arc voltage
(b) Produce hazardous fumes
(c) Slow down the welding speed
(d) Produce lack of fusion defects
ANS : B
48. Which of the following processes would be most prone to lack of fusion defects:
(a) Pulsed arc MIG
(b) Spray transfer MIG
(c) Dip transfer MIG
(d) Submerged arc
ANS : C
49. Adjusting the inductance control in dip transfer MIG / MAG welding, will control:
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(a) The pulse rate
(b) The gas flow rate
(c) The amount of spatter
(d) The arc voltage
ANS : A
50. Which of the following is an inspection point in Sub Arc Welding?
(a) Flux mesh size
(b) Gas type
(c) Tungsten size
(d) Gas flow rate
ANS : A
51. Why is Hot Pass so called?
(a) Because it is applied to a high amperage
(b) Because it is applied when the root is still hot
(c) Because it could cause hot shortness
(d) Because it heat treats the root
ANS : B
52. Which of the following is not inert gas?
(a) Argon
(b) Xenon
(c) Carbon dioxide
(d) Helium
ANS : C
53. Why is a welding arc shielded?
(a) To eliminate hydrogen
(b) To retard the cooling rate of the weld
(c) To eliminate the atmosphere
(d) To ensure maximum heat input
ANS : C
54. Which welding process is considered to be the most versatile?
(a) SAW
(b) TIG
(c) MIG / MAG
(d) MMA
ANS : D
55. The HAZ associated with a weld is:
(a) The melted portion of the parent plate
(b) The area immediately adjacent to the weld which has undergone a micro
structural change
(c) The weld area plus the parent plate which has undergone a micro structural
change
(d) The are in the weld region with the lowest tensile strength
ANS : B
56. A crack in a weld zone:
(a) Is repairable
(b) Always results in a cut out and complete re-weld
(c) Is acceptable up to 2mm in length
(d) May be repaired or cut out depending on specification requirements
ANS : D
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57. If the amperage is too low during the welding of a root bead, the possible result
would be:
(a) Lack of penetration
(b) Lack of fusion
(c) The freezing of the electrode
ANS : D
58. Pre-heating prior to welding:
(a) Must always be carried out
(b) Need not be carried out if post heat treatment is to follow welding
(c) Is always carried out using gas flames
(e) None of the above
ANS : E
59. Cold lap in another term for:
(a) Lack of fusion
(b) Low amperage
(c) Undercut
(d) Hydrogen cracking
ANS : A
60. When a medium to high carbon steel is quenched:
(a) It becomes malleable
(b) Its hardness increases
(c) It becomes ductile
(d) The plasticity is increased
ANS : B
61. The TIG welding process utilizes an electrode that is:
(a) Cellulosic
(b) Non consumable
(c) Consumable
(d) None of the above
ANS : B
62. Another name for Suckback in the root of a weld is:

(a) Concavity
(b) Convexity
(c) LORP
(d) Root undercut
ANS : A
63. One of the advantages of a multi-pass MMA weld is that it generally produces a:
(a) High tensile strength
(b) High degree of ductility
(c) Coarse grain structure
(d) Fine grain structure
ANS : C
64. A Normalising heat treatment process is carried out by:
(a) Heating the metal just above 650*C
(b) Taking the metal above the re-crystallization temperature and allowing to air
cool
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(c) Taking the metal above the re-crystallization temperature and allowing to
furnace cool
(d) Taking the metal above the re-crystallization temperature and quickly cooling
by immersing
ANS : B
65. The extent of the changes in microstructure will depend on the following:
(a) Material composition
(b) Heat input
(c) The rate of cooling
ANS : D
66. The British code for visual inspection requirements is:
(a) BS 4872
(b) BS 499
(c) BS 4870
ANS: D
67. A code of practice for visual inspection should cover the following:
(a) Before, During and After welding activities
(b) Before welding activities only
(c) After welding activities only
ANS : A
68. Incomplete root penetration in a butt joint could be caused by:
(a) Excessive root face width
(b) Excessive root gap size
(c) Low current setting
(d) Both A & C
ANS : D
69. Incomplete root fusion would certainly be caused by:
(a) Linear misalignment
(b) Incorrect tilt angle
(c) Differing root face widths
ANS : D
70. You notice a very “yeed ” ripple shape. This is most likely caused by:
(a) Poor consumable choice
(b) Welding position
(c) Excessive travel speed
ANS : C
71. “Toe Blending” is important as it may affect:
(a) Toughness
(b) Fatigue life
(c) Penetration
ANS : B
72. Slag inclusions may occur with:
(a) Manual Metal arc
(b) Metal Inert Gas
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(c) Submerged Arc Welding
(d) Both A & C
ANS: D
73. Undercut is caused by:
(a) Excessive amps
(b) Excessive volts
(c) Excessive travel speed
ANS : D
74. Undercut is normally assessed by:
(a) Its depth
(b) Its length
(c) Its blending
ANS: D
75. A welding procedure is useful to:
(a) Give information to the welder
(b) Give information to the inspector
(c) Give “Confidence” to a product
ANS: C
76. An essential variable may:
(a) Change the properties of the weld
(b) Influence the visual acceptability
(c) Require re-approval of the weld procedure
ANS : D
77. A magnifying glass may be used during visual inspection by typical magnification
would be:
(a) Up to 50 Ø
(b) 2 – 2.5 Ø
(c) 50 – 100 Ø
ANS : B
78. When visually inspecting a fillet weld, it would normally be “Sized by”:
(a) The leg lengths
(b) The actual throat thickness
(c) The design throat thickness
(d) Both A & C
ANS : A
79. A planar defect is:
(a) Incomplete fusion defects
(b) Slag inclusion
(c) Incomplete penetration
(d) Both A & C
ANS : D
80. Penetrant inspection and MPI are mainly used to:
(a) Aid visual inspection
(b) Because the application standard says so
(c) To confirm “Visual uncertainties”
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ANS : D
81. Defects outside of the limits specified in a standard should always be:
(a) Repaired
(b) Reported to a “senior person”
(c) Radio graphed
ANS : A
82. MIG welding tends to be susceptible to lack of fusion problems. This is because of:
(a) Poor maintenance of equipment
(b) Incorrect settings
(c) Poor inter run cleaning
ANS : D
83. MMA electrode can be grouped into three main types. These are:
(a) Basic, Cellulosic and Rutile
(b) Neutral, Cellulosic and Rutile
(c) Basic, Cellulosic and neutral
ANS : A
84. The main causes of porosity in welded joints are:
(a) Poor access
(b) Loss of gas shield
(c) “Dirty” materials
ANS: D
85. Cracks in welds may be due to:
(a) Solidification problems
(b) Hydrogen problems
(c) Excessive stresses
ANS : D
86. Welding a single V butt with laminations showing on the side wall may give rise
to:
(a) Lamellar tearing
(b) Solidification cracking
(c) Martensite
(d) Undercut
ANS : A
87. With reference to a root penetration bead, you could certainly assess:
(a) Root fusion and penetration
(b) Root concavity
(c) Burn through
ANS : D
88. A fatigue failure is characteristic by the appearance of the fracture surface. It would
be:
(a) Rough and torn
(b) “Cheveron” – like
(c) Smooth
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ANS : B
89. “Stray arcing” may be regarded as a serious defect. This is because:
(a) It may reduce the thickness dimension of a component
(b) It may cause liquation cracks
(c) It may cause hard zones
ANS : C
90. Overlap in welds could be influenced by:
(a) Poor welding technique
(b) Welding process
(c) Welding position
ANS : D
91. Flame cut preparation may, during welding, increase the likelihood of:
(a) Cracking
(b) Misalignment problems
(c) Inclusions
ANS : D
92. Macroscopic examination requires any specimen to be inspected:
(a) Once after welding
(b) Twice – once before and once after etching
(c) Using a microscope
ANS : B
93. Which of the following may be classed as a “More serious defect”?
(a) Slag inclusions
(b) Fusion defects (Inter run)
(c) Fusion defects (Surface)
(d) Porosity
ANS : C
94. A code of practice is:
(a) A standard for workmanship only
(b) A set of rules for manufacturing a specific product
(c) Levels of acceptability of a weldment
ANS : B
95. Movement of the arc by magnetic forces in MMA welding is termed:
(a) Arc deviation
(b) Arc misalignment
(c) Arc blow
(d) Arc eye
ANS : C
96. A metallurgical problem most associated with Submerged Arc welding is:
(a) Hydrogen cracking in the HAZ
(b) Solidification cracking in the weld metal
(c) Hydrogen cracking in the weld metal
(d) Lamellar tearing in the weld metal
ANS : B
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97. Oxy pressure and nozzle size would influence what in flame cutting:
(a) The temperature required for cut initiation
(b) The ability to cut Stainless steel
(c) The depth of cut obtainable
ANS : C
98. The main usage of arc cutting / gouging processes is in:
(a) The cutting of single bevel preparation
(b) The removal of deposited welds
(c) The cutting of single U-type preparation
(d) The cutting / gouging of non-ferrous materials only
ANS : B
99. Which of the following processes joints metals plastically:
(a) Friction welding
(b) Resistance welding
(c) Plasma welding
ANS : A
100. Which electrode classification would be relevant to AWS A5.1 / 81:
(a) E 6013
(b) E 5133
(c) E 7018
(d) Fleet weld 5
ANS : C
101. Which of the following coatings associated with “Stove Welding”?
(a) Rutile
(b) Cellulosic
(c) Basic
(d) Oxidizing
ANS : B
102. A common gas / mixture used in MIG welding nickel alloys to combine good
levels of penetration with good arc stability would be:
(a) 100 % CO2
(b) 100% Argon
(c) 80% Argon 20% CO2
(d) 98% Argon 2% Oxygen
ANS : B
103. The type of SAW flux is more resistant to moisture absorption:
(a) Fused
(b) Agglomerated
(c) Basic
(d) All of the above the same resistance
ANS : A
104. The flame temperature of oxy / acetylene mixture gas is given as:
(a) 3200* C
(b) 2300* C
(c) 5000*C
ANS : D
105. A large grain structure in steels said to produce:
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(a) Low ductility values
(b) Low fracture toughness values
(c) High fracture toughness values
(d) High tensile strength
ANS : B
106. The likelihood of brittle fracture in steels will increase with:
(a) A large grain formation
(b) A reduction of in-service temperature to sub zero levels
(c) Ferritic rather than austenitic steels
ANS : D
107. Repair welding is often more difficult than production due to:
(a) The material being ingrained with in-service contaminates
(b) Restricted access within the repair area
(c) The possible position of the weld repair
(d) Any of the above
ANS : D
108. Hydrogen cracking in the weld metals is likely when welding:
(a) Carbon Manganese steels
(b) Stainless steels
(c) Micro alloyed steels (HSLA)
(d) Low carbon steels
ANS : A
109. EN standard 288 would refer to which of the following:
(a) Welder approval testing
(b) Welding equipment
(c) Welding procedure approval
(d) Consumables for Submerged arc welding
ANS : A
110. Porosity is caused by:
(a) Entrapped slag in the solidifying weld
(b) Entrapped gas in the solidifying weld
(c) Entrapped metallic inclusions in the solidifying weld
ANS : B
111. In a bend test, the face of the specimen is in tension and root is in compression, the
type of test being carried out would be:
(a) A root bend test
(b) A side bend test
(c) A face bend test
ANS : C
112. Ultrasonic testing is of advantage in detecting which of the following weld
imperfection over other NDT method:
(a) Lack of side wall fusion
(b) Surface undercut
(c) Incompletely filled groove
(d) Overlap
ANS : A
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113. The process of tempering is often carried out to regain toughness after which of the
following processes:
(a) Annealing
(b) Normalising
(c) Hardening
(d) Stress relieving
ANS : C
114. The presence of iron sulphide in the weld metal is most likely to produce which of
the following upon contraction of the weld:
(a) Solidification cracking
(b) Hydrogen cracking
(c) Intergranular corrosion
(d) Stress corrosion cracking
ANS : A
115. When visually inspecting a completed single V butt cap you would certainly assess:
(a) Cap height
(b) Toe blend
(c) Weld width
(d) A, B & C
ANS : D
116. Generally the most suitable method of detecting lack of side wall fusion would be:
(a) UT
(b) MPI
(c) RT
(d) PT
ANS : A
117. Hot shortness is a term used to indicate:
(a) Lamellar tearing
(b) Solidification cracking
(c) Hydrogen cracking
ANS : B
118. The use of cobalt as an isotope would generally be used on:
(a) Thin material
(b) Tee joints
(c) Plate thickness greater than 25mm
ANS : D
119. In welding procedure terms, a change in essential variable means:
(a) Re-qualification of the weld procedure
(b) Possible changes in the weld’s micro structure
(c) Possible changes in the mechanical properties
ANS: D
120. Weld symbols placed on a dotted line in accordance with ISO requirements means:
(a) Weld on “Arrow” side
(b) Weld on “Other” side
(c) Weld on site
(d) Full penetration
ANS : B
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121. A welding inspector’s main attribute includes:
(a) Knowledge and experience
(b) Literacy
(c) Honesty and integrity
ANS : D
122. The correct term for a joint prepared on one component only is:
(a) A bevel butt
(b) A “J” butt
(c) A “K” butt
ANS : D
123. Technically, a code of practice is:
(a) A standard
(b) A “Set of rules for the manufacture of a product”
(c) Related to welder and weld procedure approval
ANS : B
124. The correct term for “cap height” is:
(a) Reinforcement
(b) Cap profile height
(c) Excess weld metal
ANS: C
125. A tensile test will assess:
(a) Impact values
(b) Stress
(c) Strain
(d) Both B & C
ANS : D
126. The important point of high temperature steels is that:
(a) They can withstand creep failure
(b) They may suffer re-heat cracking problems
(c) They may suffer loss of toughness
ANS : A
127. An austenitic stainless steel may suffer:
(a) Weld decay
(b) Sensitisation
(c) Solidification cracking
ANS : D
128. Carbon equivalent values are useful to determine:
(a) Weldability aspects

(b) Crack sensitivity aspects
(c) Typical mechanical properties
ANS : D
129. A basic electrode would normally:
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(a) Have superior mechanical properties
(b) Require baking before use
(c) Not be used on low carbon steels
(d) Both A & B
ANS : D
130. When referring to TIG welding, the shielding gas could be:
(a) Argon + Hydrogen
(b) Argon + Helium
(c) Argon + Nitrogen
ANS : D
131. When referring to MIG welding, the shielding gas could be:
(a) Argon
(b) Argon + 1% oxygen
(c) Argon + 20% CO2
ANS : A
132. Submerged arc utilizes:
(a) Deep penetration characteristic
(b) High deposition rates on DC +
(c) Flat (PA) welding only
ANS : A
133. Ultrasonic would be preferred over radiography due to:
(a) Ability to find most defects
(b) Lower skill requirement
(c) Ability to detect lamination
(d) Both A & C
ANS : D
134. The most serious defect types are:
(a) Planar
(b) Cracks
(c) Lack of fusion
ANS : B
135. Which of the following discontinuities could be as a primary processing
discontinuity often found in cast material?
(a) Fatigue crack
(b) Stress corrosion crack
(c) Porosity
(d) Lack of penetration
ANS : C
136. Which of the following discontinuities could be classified as a service induced
discontinuity?
(a) Fatigue crack
(b) Porosity
(c) Machining tear
(d) Lap
ANS : A
137. Which of the following contamination could affect the sensitivity of penetrant?
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(a) Acid
(b) Water
(c) Salts
ANS : D
138. Which of the following is a discontinuity that might be found in a forging?
(a) Shrinkage cracks
(b) Laps
(c) Cold shuts
(d) Insufficient penetration
ANS : C
139. The prime purpose of the black light for fluorescent penetrant inspection:
(a) To magnify indications
(b) To make the indications visible
(c) To develop indications
(d) To speed up inspection
ANS : A
140. In accordance with BS 5135 which of the following is applicable for scale “C” with
regards to hydrogen content per 100g of deposited weld metal?
(a) > 15 ml
(b) > 15 ml < 25 ml
(c) > 10 ml < 15 ml
(d) > 5 ml < 10 ml
ANS : A
141. Which is the correct heat input if the amps are 350, volts 32 and travel speed 310
mm / s?
(a) 2.16 kJ / mm
(b) 0.036 kJ / mm
(c) 2160 kJ / mm
(d) 36 kJ / mm
ANS : A
142. In accordance with BS 5135 what is the minimum distance the pre heat shall be
applied from the joint preparation?
(a) 100 mm
(b) 25 mm
(c) 75 mm
(d) Not specified
ANS : C
143. In accordance with BS 5135 what is the recommended minimum time allowed for
the pre heat temperature to equalize?
(a) 2 Min for each 25 mm of parent material thickness
(b) 5 Min for each 25 mm of parent material thickness
(c) 2 Min for each 50 mm of parent material thickness
(d) 5 Min for each 50 mm of parent material thickness
ANS : A
144. Which of the following best describes the elastic limit?
(a) The resistance to fracture under impact loading
(b) The maximum stress to which a material can be subjected without permanent
deformation
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(c) The amount of stress at which point the material will continue to elongate
without an increase in force applied
(d) The ability of the material to stretch and become permanently deformed
without breaking or cracking
ANS : D
145. In accordance with BS 2901 which of the following is classified as triple de-
oxidized filler wire?
(a) A 17 wire
(b) A 18 wire
(c) A 15 wire
ANS : D
146. In BS 639 an electrode classified as E51:
(a) Has an UTS value of 51,000 psi, minimum yield strength of 330 N/mm
(b) Has an UTS value of 430 to 550 N/mm, minimum yield strength of 360 N/mm
(c) Has an UTS value of 510 to 650 N/mm, minimum yield strength of 360 N/mm
(d) Has an UTS value of 510 to 650 N/mm, minimum yield strength of 330 N/mm
ANS: D
147. An E80 electrode would normally be classified in which standard:
(a) BS EN 499
(b) BS 639
(c) AWS A5.5
(d) AWS A5.1
ANS : C
148. What is an active flux?
(a) A material used to clean surfaces of the joint through continued chemical
reaction
(b) A material used to protect the molten weld pool during welding
(c) A material used to aid fusion
ANS : D
149. Which of the following is most likely to reduce the chances of arc blow?
(a) A change from ac current to dc current
(b) A change from dc current to ac current
(c) A change from dc electrode +ve to de electrode –ve
(d) A change from dc electrode –ve to dc electrode +ve
ANS : B
150. If a steel has a Ceq % of 0.48%:
(a) PWHT would always be necessary
(b) It will probably require a pre-heat temperature above 300*C prior to welding
(c) It will probably require a pre-heat temperature above 100*C prior to welding
(d) The heat affected zone will be very tough
ANS : C
151. When welding a double V butt joint with SAW process the presence of centerline
porosity may be due to:
(a) Damp flux
(b) Contaminated joint preparation
(c) Incorrect stick out lengths
ANS : D
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152. When considering the advantages of site RT over UT which of the following
applies?
(a) A permanent record produced, good for detecting defects which do not have
significant depth in relation to axis of the X-ray beam and defect identification
(b) A permanent record produced, good for detecting all surface and sub-surface
defects and assessing the through thickness depths of defects
(c) A permanent record produced, defect identification not so reliant on operator
skill
(d) No controlled areas required on site, a permanent record produced and good
for assessing the extent of pipe wall thickness reductions due to internal
corrosion
ANS : A
153. When ac only is required for welding, the power supply unit is almost always:
(a) A transformer, rectifier and a means to change the current
(b) A transformer, inverter and a means to change the current
(c) A rectifier, alternator and a means to change the current
(d) A transformer or alternator and a means to change the current
ANS : A
154. The HAZ associated with a fusion weld on steel has up to how many separate
regions of micro structure?
(a) 4
(b) 6
(c) 1
(d) 2
ANS : 4
155. The possible effects of having a travel speed too fast:
(a) Low toughness, slag inclusions and undercut
(b) High hardness, slag inclusions and a narrow thin weld bead
(c) High hardness, excessive deposition and cold laps
(d) Low toughness, poor fusion and slag inclusions
ANS : B
156. What five parameters would be checked when calibrating welding equipment for
mechanized MAG welding?
(a) Joint set up, flux coating, polarity, travel speed and amps / volts
(b) Amps / volts, WFS, gas flow rate, polarity and travel speed
(c) Amps / volts, WFS, wire diameter, polarity and travel speed
(d) Electrode stick out, WFS, amps / volts, polarity and wire diameter
ANS: B
157. Which of the following statements is true when using a flat characteristic power
source?
(a) The electrode is always dc –ve
(b) The shielding is always pure argon
(c) The wire feed speed remains constant
(d) The electrode extension will have no effect on weld quality
ANS : C
158. Which of the following will vary the most, when varying the arc length?
(a) Voltage
(b) Amperage
(c) Polarity
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ANS : A
159. Which of the following statement is true?
(a) The core wire in a MMA electrode has a higher melting point than the flux
(b) Electrode dc +ve is used when welding with the MIG / MAG welding process
(c) The HAZ of a carbon manganese steel weld usually has a lower ultimate
tensile strength than the weld
(d) All of the above are true
ANS : A
160. A multi run MMA butt weld made on C/Mn steel consists of 5 passes using 6mm
electrodes. A 12 pass weld made on the same joint using 4mm electrodes on the
same material will:
(a) Have a lower heat input and a higher degree of grain refinement
(b) Have a lower heat input and a coarser grain structure
(c) Have a lower amount of distortion and a higher degree of grain refinement
(d) Have a higher amount of distortion and a lower degree of grain refinement
ANS : B
161. The main reason for using a back purge when welding 18-8 stainless steel with the
TIG welding process is to:
(a) Control the root penetration
(b) Prevent root bead porosity
(c) Improve positional welding
(d) Prevent the formation of a dense oxide layer on the root
ANS : D
162. A typical minimum preheat temperature for an MMA weld made on steel with a
carbon content of 0.23% and manganese content of 1.3%:
(a) Preheat would not normally be required
(b) Less than 50*c
(c) A minimum of 100*c
(d) Above 280*c
ANS : C
163. Which is often the hardest part of a multi run weld made using MMA?
(a) The HAZ of the root
(b) The HAZ of the cap
(c) The root
(d) The cap
ANS : B
164. The HAZ of fusion weld:
(a) Usually has the highest tensile strength
(b) Cannot be avoided
(c) Is usually martensite
(d) Both A & B
(e) All of the above
ANS : B
165. Which of the following welding processes would you expect to use a collet:
(a) TIG / TAG
(b) MIG / MAG
(c) MMA
ANS : A
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166. Which of the following may be used for the TIG / TAG welding of austenitic
stainless steel?
(a) Lathanum electrode dc –ve
(b) Cerium electrode dc –ve
(c) Zirconium electrode ac
(d) Thorium electrode dc –ve
ANS : B
167. Which of the following standards is entitled electrode wire and fluxes for
submerged arc welding process of carbon steel and medium tensile steel?
(a) BS 639
(b) BS 2901
(c) BS 2633
(d) BS 4165
ANS : D
168. Which of the following processes use a constant Voltage characteristic?
(a) Sub-arc < 1000 amps, MMA, Electro slag
(b) TIG / TAG, Sub-arc > 1000 amps, Electro slag
(c) Sub-arc < 1000 amps, MIG / MAG, Electro slag
(d) MIG / MAG, Sub-arc > 1000 amps, Electro slag
ANS: C
169. What are the possible results of having a too lower heat input?
(a) An increase in hardness, lower yield strength and lack of fusion
(b) A reduction in toughness, hydrogen entrapment and an increase in hardness
(c) Entrapped hydrogen, an increase in hardness and lack of fusion
(d) Entrapped hydrogen, a reduction in carbon content and lack of fusion
ANS : C
170. What kind of steel is used for making filler rod?
(a) Killed steel
(b) Rimming steel
(c) Carbon steel
ANS : B
171. Which of the following is not related to weld?
(a)
(b)
(c)
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172. Which of the following NDT method is not suitable to detect sub surface defect?
(a) UT
(b) PT
(c) RT
(d) MPI
ANS: B
173. SAW in single pass weld will give:
(a) Poor profile
(b) Burn rapidly
(c) Good penetration
ANS : C
174. In SAW process if voltage and current is increased and travel speed is decreased,
what will be the effect in the profile?
(a) Wider weld
(b) Higher weld reinforcement
(c) Concave weld surface
175. What change will occur on the HAZ during heating of metal caused by welding?
(a) Change in tensile strength
(b) Change in hardness
(c) Change in grain crystal structure
ANS: C
176. What types of electrodes needs extra treatment?
(a) Basic
(b) Rutile
(c) Cellulosic
ANS : A
177. Applying preheat when welding, carbon manganese steel is normally done to
avoid:
(a) Slag inclusions
(b) Hydrogen cracking
(c) Lack of side wall fusion
(d) Porosity
ANS : B
178. Which of the following mechanical properties of a weld in carbon manganese steel
is not affected if the heat per unit length of weld is excessively high?
(a) Elongation
(b) Tensile strength
(c) Hardness
(d) Toughness
ANS : A
179. You observe centerline cracking in a weld that has been made at one of five work
station each making similar components. The first action to take is:
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(a) Impound all welding consumables
(b) Report the occurrence to a higher authority
(c) Stop all welding
(d) Call for full NDT checks
ANS : B
180. Which of the following defects is unlikely to be found by visual inspection?
(a) Linear misalignment
(b) Undercut
(c) Overlap
(d) Linear slag inclusions
ANS : D
181. Which of the following welding processes uses a resistive heating system to
achieve weld metal deposition?
(a) MMA
(b) SAW
(c) Electro slag welding
(d) Resistance spot welding
ANS : C
182. What two functions in arc welding must be in equilibrium to enable a stable arc to
be established?
(a) Arc voltage
(b) Current
(c) Wire / Electrode feed rate
(d) Metal burn off rate
183. In MMA welding, what parameter is used to control the penetration into the base
material?
(a) Voltage
(b) Welding speed
(c) Iron powder in the coasting
(d) Current
ANS : B
184. In the welding of a butt joint made from one side, which of the following controls
the profile of the root bead?
(a) Root face
(b) Bevel angle
(c) Root gap
ANS : C
185. What type of power source characteristic is required for manual welding?
(a) Constant voltage
(b) Flat characteristic
(c) Drooping Characteristic
(d) Motor generator
ANS : C
186. Which of the following destructive test would indicate the toughness of weld metal
and parent metal – HAZ?
(a) Macro
(b) Nick break
(c) Hardness
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(d) Charpy vee notch
ANS : D
187. Degreasing components are essential for quality welding but some agents may:
(a) Cause corrosion problems
(b) Give off phosgene gas
(c) Leave residues
ANS : D
188. In MIG ? CO2 welding which parameters give the greatest control of weld
appearance during dip transfer or short circuiting welding?
(a) Wire stick out length
(b) Amperage
(c) Wire feed speed
(d) Inductance
ANS : D
189. In MMA welding, the slag produced can be varied to suit the welding position.
Which type of slag would be required for welding in the HV position?
(a) Fluid
(b) Viscous
(c) None of the above
(d) Semi fluid
ANS : B
190. The weld metal deposit of MMA electrodes, achieves its mechanical strength
through:
(a) The core wire
(b) The flux coating
(c) Iron powders with the flux coating
ANS : B
191. What constituent is needed in a coating of an electrode to prevent the formation of
porosity in welding of a rimming steel?
(a) Iron powders
(b) Calcium fluoride
(c) Silicon
(d) Calcium carbonate
ANS : C
192. Welds made with high heat inputs show a reduction in one of the following
properties:
(a) Ductility
(b) Toughness
(c) Fatigue strength
(d) Mechanical strength
ANS : B
193. In X-ray the quality of radiographic negative is assessed by the:
(a) Density of the film
(b) IQI Indicator
(c) KVA available
(d) Stand – off distance
ANS : B
194. A steel described as QT will have improved tensile properties because it has:
(a) Had control of chemical composition
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(b) Been heat treated
(c) Been quality tested
(d) Been vacuum melted
ANS : B
195. Which one of the following type of steels would give rise to the formation of
porosity when autogenously welded with an arc process?
(a) Fully killed steel
(b) Semi killed steel
(c) Rimming steel
(d) Fine grained steel
ANS : C
196. In SAW, the use of excessively high voltage would result in:
(a) Insufficient flux melting
(b) Excessive flux melting
(c) Slag removal difficulties
(d) Spatter
ANS : B
197. The use of cellulosic electrodes is often made when welding the root pass of pipes
in the field. This is because:
(a) H2 control is needed

(b) Iron powders in the electrode
(c) Higher arc voltage can be obtained
(d) Shorter arc length can be achieved
ANS : C
198. In the welding of austenitic stainless steels, the electrode and the plate material can
be purchased with low carbon contents. The reason for this is to prevent:
(a) Cracking in the HAZ
(b) The formation of chromium carbides
(c) Cracking in the weld metal
(d) Distortion
ANS : B
199. Submerged arc fluxes can be supplied in two forms. These are:
(a) Sintered and agitated
(b) Agitated and fused
(c) Crushed and agglomerated
(d) Fused and agglomerated
ANS : D
200. In a steel which has improved creep properties at elevated temperature, which one
of the following elements helps in this improvement?
(a) Tungsten
(b) Manganese
(c) Molybdenum
(d) Carbon
ANS : C
201. Welding a steel plate of a CE of 0.45, would require preheating to:
(a) Prevent the formation of sulphides
(b) Prevent hardening in the HAZ
(c) Prevent the formation of carbides
(d) To improve mechanical properties in the weld
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ANS : B
202. Which one of the following processes uses the “Key holing” system of fusion?
(a) Friction welding
(b) Diffusion welding
(c) Electron beam welding
(d) Autogenous TIG welding
ANS :
203. In friction welding, is the metal at the interface in the:
(a) Liquid state
(b) Solid state
(c) Plastic state
(d) Elastic state
ANS : C
204. Welding procedures may require welds to be deposited at a controlled rate heat
input. High heat input would:
(a) Have poor profile

(b) Have larger grain size
(c) Have high hardness in the HAZ
(d) Have low elongation properties
ANS C
205. BS 499 part II communicates by the use of symbols the type of joint preparation to
be used. Listed below are four symbols. Which of these indicates the depth of
penetration of the weld required on the joint?
(a)
(b)
10
10
(c)
10
10
(d)
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5
ANS: B
206. In accordance with BS 499 what is the weld junction?

(a) The area containing HAZ and weld metal
(b) The weld metal and parent metal
(c) The boundary between the fusion zone and HAZ
(d) The part of the weld, which undergoes metallurgical change due to heat from
welding
ANS : C
207. Which of the following are essential factors for lamellar tearing?
(a) High residual stresses, poor through thickness ductility, existing plate
Laminations
(b) Poor through thickness ductility, fusion face parallel with rolled direction of
parent plate, most commonly occurs in but welds
(c) Stress, poor through thickness ductility, fusion face parallel with rolled
direction of parent material
(d) Tensile stress, deoxidized parent plate, poor through thickness ductility
ANS : C
208. In gas welding, leftward welding is described in BS 499 as:
(a) The flame is described towards the welded part and filler material is directed
toward un-welded part of the joint
(b) The flame and filler material both directed towards welded part of the joint
(c) The flame is directed towards the un-welded part and filler material is directed
towards welded part of the joint
(d) The flame and filler material is both directed towards un-welded part of the
joint
209. Which of the following is not a fusion welding process:

(a) Thermit welding
(b) Electro slag welding
(c) Laser welding
(d) Friction welding
ANS : D
210. When considering the heat treatment process of tempering:
(a) This is achieved by slowly heating the material to a temperature between
200*c to 650*c and slow cooling in air
(b) This is achieved by heating the material to around 200*c and soaking for
approximately 10 – 12 hrs and cooling down in air
(c) Very fast cooling form the austenite region
(d) All of the above could give a temper
ANS : B
211. Which of the following are essential variables for PWHT?
(a) Heating rate
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(b) Temperature attained
(c) Cooling rate
ANS : D
212. Most metals expand when heated, the change in length is expressed as:
(a) Thermal conductivity
(b) Modulus of elasticity
(c) Coefficient
(d) Yielding
ANS : C
213. In TIG welding the nozzle is usually made:
(a) Copper
(b) Aluminum
(c) Ceramic
(d) Copper / Zinc
ANS : C
214. Which of the following is the odd out?
(a) Neon
(b) Xenon
(c) Argon
(d) Nitrogen
215. The welding arc could be characterized as:
(a) A high current, low voltage arc with a flow of electrons from cathode to anode
(b) A low current, high voltage arc with a flow of electrons flowing from anode
(c) A medium current and medium voltage with a flow of electrons and +ve ions
flowing from anode to cathode
(d) A voltage which always remains constant at a constant potential with a flow of
electrons and –ve ions from cathode to anode
ANS :
216. Which of the following are considered to be HAZ cracks?
(a) Solidification cracks, lamellar tearing and reheat cracks
(b) Reheat cracks, liquation cracks and solidification cracks
(c) H2 cracks, solidification cracks and liquidation cracks
(d) Reheat cracks, liquation cracks and H2 cracks
ANS : D
217. Which of the following standards entitled Visual inspection of fusion welded
joints?
(a) BS 4515
(b) BS 5289
(c) BS 5135
(d) BS EN 440
218. In general it is not easy to mechanise the MMA welding process because:
(a) Short electrode length, the control of the arc length and the process uses a flat
characteristic
(b) Short electrode length, the control of the arc length and flux coverings
(c) The control of the arc length, stop start problems and short electrode length
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(d) Flux coverings, short electrode lengths and relationship between amps and
volts
ANS : B
219. Which of the following statements is true?
(a) Oxygen-fuel gas cutting is essentially an oxidization thermal cutting process
(b) Oxygen-fuel gas cutting is essentially a melting process
(c) The only fuel gas used is acetylene
(d) Propane is the preferred fuel gas in oxygen-fuel gas cutting as it produces
hotter flame
ANS : A
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220. Which of the following best describes a semi automatic welding process?
(a) The welder is responsible for the arc gap and travel speed
(b) The welder is responsible for the travel speed only
(c) The welding plant controls both travel speed and arc gap but under constant
supervision
(d) The welding plant controls both travel speed and arc gap, no supervision
required
ANS : B
221. Which sub atomic particle has a +ve charge?
(a) A proton
(b) A photon
(c) An electron
(d) A neutron
ANS : A
222. Which material is the most susceptible to reheat cracking?
(a) High carbon steel
(b) Killed steel
(c) Creep resistant steels
(d) Austenitic steels
ANS : C
223. Three essential factors for producing fusion weld are melting, removal of surface
oxide from the joint surfaces and elimination of atmosphere from the region of the
arc. Name the fourth one:
(a) The weld must be free from stress
(b) The filler material must match that of the weld
(c) The completed joint must at lease match the mechanical properties
(d) An arc for a heat surface
ANS : D
224. Which arc welding process technique is likely to be used to repair localized
porosity in a weld?
(a) MMA – PG position
(b) Mechanised arc welding
(c) Sub Arc
(e) None of the above
ANS : E
225. A welder qualified in the PG position would normally be qualified for welding:
(a) All diameters of pipe
(b) Welding positions PA, PG and PF
(c) In position PG only
(d) All pipe wall thickness
ANS : B
226. Name the fourth weld process crack which has a totally different formation
mechanism to HICC (H2 induced cold crack), solidification cracking and lamellar
tearing:
(a) Liquation cracking
(b) Reheat cracking
(c) Crater cracking
(d) Hot tearing
ANS : B
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227. Planar defect are best described as:
(a) Linear from at least one direction
(b) Rounded indications
(c) Linear from at least one direction with volume
(d) May be classed as all of the above
ANS : A
228. Which of the following welding processes is not classed as an arc welding process?
(a) Electro slag welding
(b) Thermit welding
(c) Plasma welding
(d) Both A and B
(e) All of the above
ANS : B
229. Which of the following materials has the poorest weldability?
(a) Austenitic stainless steel
(b) Martensitic stainless steel
(c) Carbon manganese steel
(d) HSLA steel
ANS : B
230. Which of the following in a fusion weld usually has the highest tensile strength?
(a) Weld metal
(b) Parent material
(c) HAZ
(d) Fusion zone
ANS : HAZ
231. Which of the following is an alternative name for a crater crack?
(a) Cold crack
(b) Tearing
(c) Star crack
(d) Fatigue crack
ANS : C
232. What action must the welding inspector request if a lamination is found extending
into the bevel face?
(a) Cut back the material until a lamination free area is found
(b) Accept the bevel unless the lamination exceeds 5mm
(c) Place a sealing run over the lamination and dress flush, then make the weld as
normal
(d) Action to take will depend on the agreed specification (or welding
engineer/client if specification does not state the action).
ANS : D
233. The deviation of the arc during arc welding due to external magnetic influences is
known as:
(a) Arc strike
(b) Arc blow
(c) Paramagnetic interference
(d) Diamagnetic interference
ANS : B
234. The weldability of a material may be affected by:
(a) Temperature of the component
(b) The Ceq % of the material
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(c) The elements in the material
ANS : D
235. Which of the following heat treatment processes would be used for grain
refinement?
(a) Annealing
(b) Normalizing
(c) Quenching
(d) H2 release
ANS : A
236. A repair has been made using MMA on a double V butt weld on a 10 m diameter
tank. The defect repaired was lack of inter-penetration and it had been excavated
with a disc grinder prior to repair. After repair it was determined that the wrong
electrodes had been used. What action should the inspector take:
(a) Have the repair area ground and re-repair
(b) Accept the work if the electrodes were the same flux type
(c) Heat treat the area
(d) Consult the senior inspector or welding engineer if the specification or
procedure does not cover the course of action
ANS : D
237. Which one of the following statements is false?
(a) Surface breaking defects are usually more detrimental to a weld in comparison
with sub-surface defects
(b) The HAZ’s of a steel weld usually have h higher tensile strength than the weld
metal
(c) Lameller tearing may occur within the fusion zone of large fillet welds
(d) PWHT may stress relieve
ANS: B
238. What is the possible cause of too much restraint of the parent material during
welding?
(a) Restraint is always desirable
(b) It may lead to cracking, especially with small welds between large
components
(c) It will cause too much distortion
(d) It will cause lamellar tearing if it is present on a corner joint
ANS: B
239. Fluctuating loads ie cyclic stresses below the u.t.s on a weld component may lead
to:
(a) Tensile failure
(b) Yield failure
(c) Fatigue failure
(d) Shear failure
ANS: C
240. Which of the following is a method to accurately measure the root radius of a
charpy or izod specimen?
(a) Use a machine called a shadowgraph
(b) Use pyrometer
(c) Use a vernier caliper
(d) Use a densitometer
ANS : A
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(a) Fillet welds are preferable to butt welds due to high strength
(b) Fillet welds are normally difficult to assess with NDT in comparison with butt
welds
(c) Fillet welds are only made on steels
(d) All of the above are true
ANS : B
242. Which of the following is not an inert gas at welding temperature?
(a) Argon
(b) Neon
(c) Carbon dioxide
(d) Helium
ANS : C
243. Which arc welding process uses a non consumable electrode?
(a) MIG
(b) TIG
(c) SAW
ANS: B
244. Which of the following welding processes is not a fusion welding process?
(a) Electro slag welding
(b) Oxy-gas welding
(c) Forge welding
(d) TIG welding
ANS: C
245. Which of the following current types would be used for welding aluminum with the
TIG welding process?
(a) Ac
(b) Dc +ve electrode
(c) Dc –ve electrode
(d) All of the above could be used successfully
ANS : A
(a) Electrode dc +ve always produces a narrow deep weld pool
(b) The word Rutile means calcium carbonate
(c) Porosity is always repairable
(d) Dc electrode +ve is used for the MAG welding of steel
ANS : D
247. What four criteria are necessary to produce HICC?
(a) Hydrogen, moisture, martensite and heat

(b) Hydrogen, poor weld profile, temperature above 200*c and slow cooling
(c) A grain structure susceptible to cracking, stress, hydrogen and a temperature
below 200*c
(d) Weld defects, pearlite, hydrogen and a temperature above the melting point for
the material
ANS : C
248. How many temperature indicating crayons would be required to ensure the preheat
temperature was lying within a specified range?
(a) 1
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(b) 2
(c) 3
(d) As many as possible
ANS: A|D
249. A carbon equivalent of 0.48%:
(a) Is hig for a C-Mn steel and may require a preheat temperature over 100*c
(b) Is insignificant for a C-Mn steel and preheat will not be required
(c) Is calculated from the heat input formula
(d) Is not a consideration for determining preheat temperature
ANS : A
250. A martensite grain structure:
(a) Is always present in welds on steel
(b) Is brittle grain structure
(c) Is obtained when the preheat temperature exceeds 200*c
ANS: D
251. Which of the following is not a type of crack?
(a) Fissure
(b) Lamellar tear
(c) Fish eye
(d) Reheat crack
ANS : A
252. What do you understand by the term minimum interpass temperature?
(a) Minimum post heat temperature
(b) Minimum stress relief temperature
(c) The lowest temperature to be used when normalising
(d) The lowest temperature allowed during welding and between passes
ANS : D
253. Which of the following welding processes may be described as a low H2 process in
comparison with MMA welding?
(a) TIG
(b) MIG
(c) MAG
ANS : D
254. Which of the following standards is entitled imperfections in Metallic fusion welds
with explanation:
(a) BS EN 25817
(b) BS EN 26520
(c) BS EN 22553
(d) BS EN 24165
255. Which of the following could cause root concavity?

(a) Excessive back purge pressure and very high heat input
(b) Excessive back purge pressure and entrapped gas
(c) Excessive root grinding and a slow travel speed
(d) Excessive root grinding and excessive back pressure
ANS : D
256. High Phosphorous contents in carbon steels may cause:
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(a) Cold shortness
(b) Hot shortness
(c) An increase in ductility
(d) An increase in malleability
ANS : A
257. If arc strikes are found on carbon steel (C eq of 0.5%), what undesirable grain
structure may be present?
(a) Perlite
(b) Martensite
(c) Bainite
(d) All of the above are undesirable grain structures in constructional steels
ANS: B
258. How do you convert psi to N/mm2?
(a) Divide by 144.9
(b) Multify by 25.4
(c) Divide by 14.7
(d) Multify by 14.7
259. How many Mpa are equal to 1 N/mm2?

(a) 144.9
(b) 25.4
(c) 14.7
(d) 1.
260. What is the UTS of a material?

(a) The proof stress
(b) The maximum load a specimen can withstand
(c) The limit of proportionality
(d) The point of plastic deformation
ANS : B
261. What is a charpy test used for?
(a) To measure the ductility of a material
(b) To test the tensile strength of a material
(c) To test the notch toughness of a material
(d) To measure crack propagation speed
ANS : C
262. What is a Vickers Pyramidal Indentor used for?
(a) To measure indentation toughness
(b) To measure ductility
(c) To measure hardness
ANS: C
263. What is the main constituent of a rutitle electrode flux?
(a) Cellulosic
(b) Titanium dioxide
(c) Calcium carbonate
(d) Asbestos
ANS : B
264. What does the 70 represent on a E 7010 AWS classified electrode?
(a) 70 N/mm2 minimum uts
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(b) 70 N/mm2 minimum impact strength
(c) 70,000 psi minimum uts
(d) 70,000 psi minimum impact strength
265. Basic coated electrodes provided in standard packaging:

(a) Are deep penetrating electrodes
(b) Should be heated prior to welding to obtain a low H2 content in the weld
(c) Should be heated to totally eliminate H2 in the weld
(d) Should not be preheated as this will detrimentally effect welding performance
ANS : B
266. Sodium silicate in an MMA electrode flux:
(a) Stabilizes the arc
(b) Binds the ingredients of the flux
(c) Forms slag
ANS : D
267. Which electrodes are very susceptible to causing porosity in the deposited welds if
long arc employed?
(a) Basic
(b) Cellulosic
(c) Rutitle
(d) None of the abobe
268. What is the purpose of a rectifier?

(a) To adjust the voltage
(b) To adjust the amperage
(c) To covert ac to dc
(d) To reduce the chance of arc strike
ANS : C
269. A welding process using equipment with a flat characteristic:
(a) Will require a permanent or temporary backing to be pre placed on the root
side of the welds
(b) Has the advantage of being able to use any type or size of electrode
(c) Is likely to be using an electrode less than 2 mm dia.
(d) Is likely to be using an electrode more than 2 mm dia.
270. Which of the following best describes the duty of a welding inspector?
(a) To carry out inspection and NDT in order to find all weld flaws present
(b) To attempt to ensure that all welding and any associated actions are carried out
in accordance with agreed specification
(c) To carry out welding inspection and radiography interpretation with agreed
procedure for the work being undertaken
(d) To make sure that all the welds are defect free
271. Which of the following butt weld preparation is usually the most susceptible to lack
of side wall fusion during MMA welding?
(a) A double sided U preparation
(b) A single V preparation
(c) A double sided V preparation
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(d) It is not possible to induce lack of side wall fusion during MMA welding
272. What is the leg length of a fillet weld?

(a) The distance from the toe to the face
(b) The distance from the root to the face center
(c) The distance from the root to the toe
(d) The distance from the toe to the toe
273. What is the throat thickness of a mitre fillet weld equal leg length?
(a) The distance from the toe to the face
(b) The distance from the root to the face center
(c) The distance from the root to the toe
(d) The distance from the toe to the toe
274. Which of the following will vary the most when varying the arc length using the
MMA process?
(a) Voltage
(b) Amperage
(c) Polarity
275. What is a possible result if the amperage is too low during the welding of a root
bead using an arc welding process with a consumable electrode?
(a) Incomplete root penetration
(b) Lack of root fusion
(c) The freezing of the electrode to the work piece
276. Why have a high OCV with MMA welding?

(a) To initiate
(b) To obtain penetration
(c) To avoid lack of fusion
(d) MMA welding does not have a high OCV
ANS : A
277. What is another term for suck back?
(a) Concave root
(b) Elongated porosity in the root
(c) Lack of penetration
(d) A slag line above the root pass
ANS: A
278. A center line crack in a fillet weld:
(a) May be repaired if the welding engineer for the client says so
(b) May be related to a poor setup
(c) May be related to the way the grains solidify
279. What is lamellar tearing?
(a) Strain cracking at the edge of bend test specimen
(b) A type of crack occurring in the parent material is associated with poor
through thickness ductility especially when large fillet welds or tee butt joints
are made on the material
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(c) A type of crack found in welds which have undergone several thermal cycles
either during welding or PWHT
(d) It is another name for a plate lamination caused during plate or pipe
manufacture
280. What is a crater pipe?

(a) Another term for concave root
(b) Another term for a burn through
(c) A type of gas pore found in the weld crater
(d) A shrinkage defect which may be found in a weld center
281. Why is a weld procedure qualification test necessary?

(a) To ensure the welder is able to make sound welds meeting the requirements of
the agreed welding procedure
(b) To ensure the welder satisfies the NDT and mechanical requirements of the
specification
(c) To give maximum confidence that the variables used for welding are
compatible and will produce sound welds meeting the requirements of the
agreed specification
(d) To give a guarantee that defect free welds are going to be produced
282. Which of the following is not specified on a typical written welding procedure?
(a) To make sure the welder can weld
(b) To make sure the weld is able to withstand stress
(c) To give maximum confidence that the welder can produce welds to meet the
requirements of the specifications(s)
(d) To make sure the welder can produce a weld free from discontinuities
283. A welder qualified in the 6G position would normally be qualified for welding:
(a) All diameter pipes
(b) All metals
(c) In all positions for the butt welds and fillet welds
284. Non-planar defects associated with a weld:

(a) Are not significant
(b) Must be removed
(c) Are not usually as significant as planar defects
(d) Only exit sub-suface
285. Lamellar tearing:

(a) Only occurs in the rolled direction of a parent material
(b) Is a HAZ type of type of crack
(c) Is another term for a lamination
ANS : A
286. Cold lapping is another term for:
(a) Lack of fusion at the toe of a weld
(b) Low amperage
(c) Undercut
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(d) Hydrogen cracking
ANS: A
287. Which of the following sentences applies to the use of basic MMA electrodes?
(a) They are used to deposit weld metal in the vertical position only
(b) They are used where deep penetration is a primary requirement
(c) They are usually used to deposit weld metal of low hydrogen content
(d) Basic electrodes are chosen when ease of use is of importance
288. Which of the following would show as light indications on a radiograph?

(a) Slag inclusions and copper inclusions
(b) Tungsten inclusions and excessive penetration
(c) Cap undercut and root piping
(d) Excessive cap height and incomplete penetration
ANS : B
289. Which of the following welding processes does not use a consumable electrode?
(a) SAW
(b) MMA
(c) TIG
(d) ESW
ANS: C
290. The hardest grain structure capable of being produced when welding C/Mn steel is:
(a) Bainite
(b) Austenite
(c) Pearlite
(d) Martensite
ANS: D
291. The presence of too much hydrogen when welding C/Mn steels would be to cause
the formation of:
(a) Porosity
(b) Lack of fusion
(c) Crack
(d) undercut
ANS: C
292. What term applies if a carbon steel weldment is heated up to a temperature which
creates austenitic grain growth and then is allowed to cool in air?
(a) Normalizing
(b) Annealing
(c) Quenching
(d) Tempering
ANS : A
293. Why is stress relief (PWHT) some times carried out on weldments?
(a) To dissolve entrapped hydrogen
(b) To remove residual stresses
(c) To fuse planar defects
294. When welding a double V butt with the SAW process the presence of center line
porosity may be due to:
(a) Damp flux
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(b) Incomplete penetration
(c) Contaminated weld preparation
(d) Atmospheric contamination
ANS: A
Which of the items below is not the tools of welding inspector
a Electrode quiver
b Various type of welding gauges
c Flash or torch lights
d Steel rule and measure tape
ANS : A
1
8 Visual Examination shall be carried out by
b a The Welder Foreman
b b A Qualified Welding Inspector
b c A Qualified Welder
b d Production Supervisor
ANS : B
Which is following could be used to prevent intercrystalline corrosion in Austenitic Stainless Steel?
a Vanadium
b Selenium
c Sulphur
d Niobium
ANS : D
Chromium molybdenum steels for high temperature service typically have their carbon contents
below 2% What other element is added to the steel to creat a stable at elevated temperatures?
a Vanadium
b Selenium
c Sulphur
d Nickel
ANS : A
Cold or Delay cracking is
a Type of cracking due to mainly of Hydrogen
b Lack of fusion between weld metal and parent metal
c Type of cracking happened both in weld and parent metal
d Both b and c
ANS: A
With reference to the various grades of stainless steel, which of the following statements is true?
a they are all non-magnetic
b they all require 100%Ar for GMAW
c they all have very high thermal conductivity
d only certain grades can be used for service at very low temperature
Carbon equivalent value (CEV) are used to determine the how to avoid the risk of …
a Solidification cracking
b hydrogen cracking
c lamellar tearing
d weld decay
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ANS: B
The use of low carbon austenitic stainless steel and stabilised stainless steel will minimise the risk of …
a HAZ cracking
b weld decay
weld metal
c
cracking
d distortion
ANS : B
1. What is meant by operating factor (O/F) in welding
a) The safety value give as the % of time a conductor can carry a current
b) The specific current at 60% and 100% in a given time I.E 350A 100%
c) The rate of weld progression
d) The arc time in hours divided by the total hours worked or the welding process operated
ANS : D
2. Surface breaking solidification cracks can be detected by:
a) RT
b) UT
c) VT
d) All of the above
ANS : C
3. In Tig (pulsed) welding which parameter can be adjusted
a) Pulse peak current
b) Pulse frequency
c) Pulse duration
d) All of the above
ANS : D
4. In the MMA process the effect of polarity on welding may be described as:
a) Electrode positive results in an increase in the depth of the weld penetration
b) Electrode negative results in decrease in the depth of the weld penetration
c) Electrode negative cause build up heat in electrode, increase electrode melting rated
d) All the above (ANS)
FINAL ASSESMENT MULTIPLE – CHOICE QUESTION
CSWIP 3.1 WELDING INSPECTOR COURSE
MFY – 001
ALL QUESTIONS TO BE ATTEMPTED
1. Which of the following does not contribute to hydrogen cracking:

a) External forces on the weldment
b) Amount of hydrogen in the weld
c) Residual stresses in the weld
d) Size and length of linear discontinuities
ANS : D
2. For the arc air carbon cutting process the air is
a) Use for cooling the electrode only
b) Produced through the chemical reaction of the electrode and the base metal
c) Supplied through air ports in the electrode holder and directed along the electrode
d) Supplied by another torch also by other operator
ANS : C
3. Acetylene hoses are distinctly difference from oxygen hoses .Why?
a. Because the internal diameters of the two are different
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b. Because of operating pressure differences between fuel gas and oxygen
c. Acetylene attacks the materials used in oxygen hoses
d. To prevent accidental interchange
ANS: D
4. Which of the following can result in a hard and brittle condition resulting from rapid cooling:
A. Arc strikes
B. Excessive weld reinforcement
c. Excessive spatter
d. Slag inclusion
ANS: A
5. DC negative when used for MIG/MAG can give smooth arc.
A. True
B. False
ANS : B
6. In which of the following process is the use of pressure required to successfully joint the materials:
A. TIG
B. MMA
c. SAW
d. Stud welding
ANS : D
7. Which of the following will contribute significantly to lack of fusion
A. Incorrect joint design
B. Incorrect welding technique
c. Heavy scale on the joint surface
d. All of the above
ANS : D
8. Which of the welding process used loose granular flux:
A. FCAW
B. SAW
c. GTAW
d. SMAW
ANS : B
9. Crack Tip Open Displacement test is used to measure

A. Strength of the material being tested
B. Hardness of the material
c. The toughness of the materials, resistance to crack extension and the acceptable flaw size all
d. Ductility of the material being tested
ANS : C
10. The pulsed MIG/MAG mode of transfer is a variation of a spray transfer mode that make used of a
low background current with a higher, rapidly pulsing current superimposed on it.
A. False
B. True
ANS: B
11. The iron carbon diagram is used by metallurgists and others to see how:
a . Adding nickel changes the corrosion resistance of steels
b . Adding carbon changes the response of the steel to temperature changes
c. adding molybdenum increases the toughness of steel
d. adding chromium improves corrosive corrosion resistance
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ANS : B
12. The main purpose of a developer is to :
a . Assist in the development of the test procedure
b . Provide a clean surface for the penetrant indication
c. Assist in the development of the penetrant indication from a defect
d. Assist in the drying of the penetrant
ANS : C
13. Overlap in a fillet weld would occur :
a . At some point in the weld throat
b . only on the face of the weld
c. At the toe of the weld
d. At the root of the weld
ANS : C
14. In the TIG welding process, gas shielding of the weld pool maybe provided
by which gas (es )
a . carbon dioxide
b . argon and oxygen
c. argon and helium
d. oxygen and helium
ANS: C
15. Welding flux :
a . Helps on control the temperature of the pieces being welded
b . Crates a temporary bond between the pieces being welded
c. Protects from the atmosphere and removes the oxide film on the surface
d. Makes it easier to move the electrode
ANS : C
16. Increasing the carbon content of steel allows a given level of hardness to be
achieved :
a . at a higher cooling rate
b . without consideration of the cooling rate
c. without adding chromium to the steel
d. At lower cooling rate
ANS : C
17. Which is not a factor that should be considered in selecting the best shielding gas mixture for a given
application:
a . weld appearance and acceptable spatter level
b . thickness,joint design and penetration requirements
c. the welder’s personal requirements
d. Transfer mode
ANS : C
18. Which of the following is not considered to be cause of incomplete fusion
a . Welding current exceeding that specified on a WPS
b . Using too large an electrode for a narrow Vee
c. Improper manipulation of the electrode
d. Using the wrong type of electrode
ANS : A
19. Which is an advantage of an argon/hydrogen gas mixture in TIG of stainless steel
a . Lower heat input
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b . Improved toughness
c. Faster travel speed
d. Improved mechanical properties
ANS : C
20. Some MMA electrodes for the welding of stainless steel have a low carbon
Steel core wire and the alloying elements in the covering. This is because :-
a . The core wire offer lower resistance to the passage of the welding
current
b . The manufacturer can more conveniently include alloying elements
in the covering than produce special core wires
c. Both for reasons a and b above
d. For some reason not listed above
ANS : D
21. Sulphur is sometimes added to steel to improve:
a . The impact properties of the welded joint
b . Provide higher impurities levels
c. Toughness of the parent materials
d. Machining properties characteristics of the steel
ANS : D
22. Slow cooling of liquid metal from high temperature promotes the growth of :
a . Medium grains
b . Large grains
c. Small grains
d. A combinations of large and small grain
ANS : B
23. A defect can best be described as :
a . All types of flaw in a weld regardless of size
b . Meaning exactly the same thing as a discontinuity
c. Any type of weld flaw
d. A discontinuity judged to possibility interfere with the fit for purpose
of the weld
ANS : D
24. A CC ( Drooping arc ) power source is suitable for
a . MMA - TIG
b . MIG/MAG - FCAW welding process
c. SAW – MIG/MAG
d. MMA – MIG/MAG
ANS: A
25. In Gas Metal Arc Welding (GMAW ) , spray Transfer may be achieved using shielding gases containing
a . More than 85 % argon
b . Less than 50 % Argon
c. 100 % carbon dioxide
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d. Less than 75% argon
ANS: C
26. When welding with a weave technique the heat input using the same welding parameters( amps and
volts ) as those used for stringer bead will be :
a . Lower than that for the stringer bead
b . Unaffected because techniques has no influence on the heat input
c. Will be higher than the stringer bead because the travel speed will be
lower
d. The same as that for the stringer bead
ANS : C
27. Welding in cold weather conditions is mostly commonly associated with
increased risk of :
a . Undercut
b . porosity
c. Slag Inclusion
d. Cracking
ANS : D
28. Hydrogen trapped in the weldment can cause hydrogen cracking if the contents of hydrogen are too
high. What is the other name commonly used to describe hydrogen cracking?
a . Fissure cracks
b . Hot cracks
c. Supercritical cracks
d. Cold cracks
ANS: D
29. Steel is often heat treated after it is made at the steel mill. When a steel is normalized what is the primary
objective of this process ?
a . To increase the hardness
b . To decrease the amount of carbon in the steel
c. To increase the low temperature toughness of the steel
d. To improve the tensile strength
ANS : D
30. The recommended drying temperatures and time required producing a
condition below 5 ml H2 / 100 grams of weld metal when using basic electrodes
would be :-
a . Below 1500 C for 1 hour
b . 250 0 C for 1 hour
c. Over 3500 C for 1 hour
d. 6000 C for 1 hour
ANS : B
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MFY – 002
1. Why is it generally good practice to aim at using the least amount of consumable materials and keep
joint preparations to a minimum?
a) To increase beneficial residual stresses
b) Improved strength
c) Smaller welds generally look better
d) To reduce costs and with less weld metal there is the probability of
fewer weld faults
ANS : D
2. In general, the MIG/MAG mode of transfer best suited for welding thin sheet is:
a. Short –circuiting transfer
b. Globular transfer
c. Spray transfer
d. Should not use MIG/MAG for welding thin sheet
ANS : A
3. In general, the MIG/MAG mode of transfer best suited for welding thick sheet is spray transfer
a. True
b. False
ANS: B
4. Which of the following maybe difficult to detect with the radiographic inspection method?
a. Incomplete penetration
b. Discontinuities pendicular to the radiation beam
c. Slag inclusion
d. Porosity
ANS : B
5. The pulsed – MIG/MAG process is only suitable for welding in the flat position
a. True
b. False
ANS: B
6. When using Gas Metal Arc Welding (GMAW) process, straight argon may be successfully used as a
shielded gas when welding the following materials(s):
a. Steel or aluminium
b. Aluminium
c. Straight argon is never used
d. Steel
ANS : B
7. The primary advantage of a 75% Ar, 25% CO2 gas mixture over pure CO2 in the FCAW process is:
a. Increase in welding speeds
b. Very significant reduction in weld spatter
c. Increase in heat input
d. Decrease in welding speeds
ANS: B
8. A cause of inadequate penetration could:
a. Incorrect joint preparation
b. Incorrect joint design
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c. Incorrect welding technique
d. All of the answer provided are possible cause
ANS : D
9. Which of the following is not a method of increasing the hardness of steel?
a. Heat treatment
b. Casting
c. Mechanical Deformation
d. Introducing alloying elements
ANS : B
10. Welding changes the properties of solid steel through:
a. Mechanical changes caused by rolling
b. Changing the final appearance of the steel
c. Heating and cooling cycles associated with the welding arc and weld metal deposit
d. Metallurgical effects as a results of micrographs
ANS: C
11. Tension test results are used:
a. Soundness of the materials being tested
b. To select material for engineering applications
c. Fracture toughness of the materials being tested
d. Fatigue capability of the material being tested
ANS : B
12. Which of the following may contribute to the formation of porosity in the weld deposit:
a. All of the answer provided is a contributing factor
b. Low welding current
c. Contamination of the weld joint surfaces
d. Use of contaminated electrodes
ANS: A
13. When using the GMAW process for the welding of aluminium, the liner should made of:
a. Nylon
b. Graphite
c. Steel
d. A liner should not be used
ANS : A
14. When preparing bend test specimens it is important to:
a. Use a proper etching
b. Prevent stress raisers by radiusing all edges of the specimen
c. Ensure the reduced section is of the correct dimensions
d. Accurately place the notch in the correct position
ANS : B
15. Steels that have intentional additions of sulphur, lead or selenium to improve machinability :
a. Can develop liquation crack in the HAZ after being welded
b. Are used for trucks axles only
c. Do not require approved procedures to be welded
d. Can not be welded
ANS : A
16. In the TIG process an arc is formed between:
a. The filler metal rod and the workpeice
b. The tungsten electrode and the filler metal rod
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c. No arc is present
d. The tungsten electrode and the workpeice
ANS : D
17. Oxygen and suphur in steels form non-metallic inclusions during the rolling process and can lead to
what during and after welding?
a. Lamellar tearing
b. Stress corrosion
c. Suphide precipitation
d. Oxygen rich welds
ANS : A
18. Smaller of finer grain structures in steel usually provide
a. Low formability
b. Higher hardness
c. Higher strength
d. Low strength levels
ANS : B
19. Arc energy or weld heat is a function of :
a. Travel speed only
b. The welders ability and does not depend on the welding parameters
c. Arc voltage and electrode type
d. Arc voltage, arc current, and travel speed
ANS : D
20. The fully transformed heat affected zone located next to the fusion boundary in a weldment is the
area
a. Where cracking does not occur
b. With a lowest tendency to form cold cracks
c. With the highest tendency to form hydrogen cracks
d. Where cold cracks will not occur
ANS : C
21. Heat-treating steel consists of three basic steps. Which of the following is not a description of the
basic steps to heat-treating?
a. Heating the steel to a specific temperature
b. Maintaining the steel at the specified temperature for a certain period time
c. Cooling the steel at a specified rate
d. Controlling the weld sequence during weld fabrication to lower stresses prior to heat treating
ANS : D
22. In MMA the molten metal is protected by:
a. The molten metal is not protected
b. External carbon dioxide shielding gas
c. External argon shielding gas
d. Gases created from the decomposition of the electrode covering
ANS : D
23. In the Gas Metal Arc Welding process, the electrical current is transferred to the electrode via the:
a. Feed rolls
b. Contact tip
c. Sleeve
d. Liner
ANS : B
24. The effective throat thickness of an incomplete joint penetration groove weld is:
79 0f 9
a. Considered to be equal to the thickness of the base metal thickness less 3 mm
b. Equal to the thickness of the base metal thickness if welded from both sides
c. Considered to be equal to the thickness of the base metal thickness less 1 mm
d. Less than the thickness of the base metal
ANS : D
25. When base metal is melted away and not replaced with weld metal this is referred to as:
a. Undercut
b. Excessive convexity
c. Lack of fusion
d. Weld crater
ANS : C
26. Defects is a term which is used to be best describe:
a. Structural discontinuities
b. Only discontinuities that have been classed as acceptable
c. Only discontinuities that have been classed as unacceptable
d. All discontinuities
ANS : C
27. An excessively large root face on a weld on a weld joint preparation:

a. Will result in excessive reinforcement
b. Will result in excessive penetration
c. Can prevent penetration to desired depth
d. Is the primary cause of lack of fusion
ANS : C
28. Which of the following would be considered the most serious structural discontinuity :
a. Lack of fusion
b. Cluster porosity
c. Slag inclusion
d. Crack
ANS : D
29. The most common value reported in a charpy – vee notch test is
a. Tension test
b. Location of fracture
c. Length of specimen
d. Absorbed energy
ANS: D
30. Metallographic examinations are used to determine the following weld characteristics:
a. Soundness of the joint and depth of penetration
b. Fracture toughness of the material being tested
c. Ductility of material being tested
d. Tensile properties of the materials being tested
ANS : A

MFY – 003
1. Which of the following mechanical properties of a weld made in carbon – manganese steel is most
80 0f 9
affected, if the heat input per unit length is excessively high: -
a) Tensile strength
b) Toughness
c) Brittleness
d) Elongation
ANS: B
2. A steel is intended for non load carrying service in air at 800 0 C – 900 0 C.What single alloying
element would you almost certainly find in order that scaling is minimised
a. Nickel
b. Chromium
c. Cooper
d. Molybdenum
ANS : A
3. The effective or design throat thickness of a complete joint penetration butt weld is
a. Equal to the thickness of the base metal thickness if welded from both sides
b. Considered to be equal to the thickness of the base metal thickness less 1.0 mm
c. Considered to be equal to the thickness of the base metal thickness less 3.0 mm
d. Equal to the thickness of the base metal
ANS: D
4. The three main modes of transfer encountered in Gas Metal arc Welding (GMAW) are: -
a. Spray, globular and drooping
b. Spray, high – arc and drooping
c. High –arc, globular and short - circuiting
d. Spray, globular and short - circuiting
ANS: D
5. Weld joints designed with J preparations are usually used only on very thick material. Why?
a. J preparations are more difficult to fit than other preparations
b. J preparations require least amount of weld filler metal for a given joint thickness
c. J preparation are expensive because they must usually be machined
d. J preparations affords limited access to the root of the joint
6. Which of the following situations is most likely to produce the greatest amount of the direct and
reflected ultraviolet light?
a. Submerged arc welding
b. Gas Metal Arc Welding aluminium plate
c. Brazing
d. Resistance welding two thin sheet steel
7. Which of the following conditions must be present for the oxyfuel gas cutting process to be effective:
a. The temperature of the metal’s oxides should be above that of the metal
b. The metal must be brought up to its melting temperature
c. The kindling temperature of the material must be above its melting temperature
d. The melting temperature of the materials must be above its kindling temperature
8. Slow cooling of liquid metal from high temperature promotes the growth of ;
a. Small grains
b. A combination of large and small grains
c. Medium grains
d. Large grains
81 0f 9
9. Dimensional discontinuities become dimensional defects when:
a. Specified by the welding inspector
b. Specified by the engineer
c. Their dimensions have been found to exceed the set limits of a specifications or code
d. There is no difference since the terms mean the same
10. The CTOD toughness depends on the following four items
b. Thickness,temperature of the specimen,loading rate and microstructure
b. Loading rate,microstructure,notch location and temperature
c. Bending radius, weld size, hardness and width of specimen
d. Notch location, weld size, thickness of specimen and temperature
11. The shielding gas that is commonly used with Flux cored Arc Welding process is:
a. Argon
b. Carbon dioxide
c. Helium
d. Hydrogen
ANS: B
12. Which is not an advantage of Helium/Argon/Carbon Dioxide mixtures for welding stainless steel
a. Short circuiting transfer can be used for joining thin materials and welding out of position
b. The high heat input of helium produces deep penetration
c. Wetting and bead appearance are good
d. They can be used on Austenitic Stainless Steel without fear of hydrogen embitterment
13. When using the GMAW process for the welding of aluminium, the liner should made of:
a. Nylon
b. Graphite
c. Steel
d. A liner should not be used
14. Which is the compulsory part of an electrode classified to BS EN as

E 46 3B 160 20 H
a. E 46 3 B 160
b. E 46 3 B 160 20
c. E 46 3 B
d. All of the above
15. In Manual Metal Arc Welding which type of flux covering gives the highest hydrogen level to
produce deep penetration
a. Iron oxide
b. Acid and oxidising
c. Rutile with addition of iron powder
d. Cellulose
16. Crater pipe in welds made by Manual Metal Arc cause by: -
a. The electrode too damp
b. Condensation of parent metal
c. Stress acting along the crater
d. Poor welder’s technique
17. When approving procedure to BS EN 288 –3 the welder: -
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a. Is automatically approved
b. Is approved to the same specification
c. Is approved to a separate specification
d. Is approved for the same range of approval
18. Which statement with regards to Open circuit voltage is not true:-
a. OCV is the voltage between the terminals when welding
b. The voltage occurs before welding or without load
c. AC machine has higher OCV compare to DC current
d. DC current more safer than AC current due to lower OCV value
19. Inverters are: -

a. Less efficient than conventional machine
b. Capable of being either CC or CV
c. Inferior in volt – ampere characteristics
d. Bulky and heavy
20. A 70 % duty cycle means that a machine may, at its rated output, run:
a. One hour out of every seven hours
b. Seven minutes out of every ten minutes
c. Forty two minutes out of every one hour continuously
d. Seven minutes out of every hour
ANS: B
21. Martensite is a hard phase in steel and is highly dependant on its properties from the amount of
carbon trapped in the Body Centered Cubic atom arrangement. When carbon is trapped in this atom
arrangement what happens to this arrangement to cause the
a. carbon atoms cause the BCC shape to distort resulting in increased hardness
b. Iron transform to pig iron
c. Carbon dissolves in the iron
d. Carbon separates out to form isolated islands martensite
ANS: A
22. Hot shortness is term used to indicate
a. Lamellar tearing
b. Hydrogen cracking
c. Solidification cracking
d. Hot electrical shock
ANS: C
23. The important point of high temperature steels is that:-
a. They can withstand creep failure
b. They may suffer re-heat cracking problems
c. They may suffer loss of toughness
d. All of the above
ANS : D
24. Ultrasonics would be preferred over radiography due to:-

a. Ability to find most defects
b. Lower skill requirement
c. Ability to detect laminations
d. Both a) and c)
ANS: C
83 0f 9
25. Argon is not generally used as a shielding gas when MIG welding carbon steel because:-
a. The price is too expensive compare with carbon dioxide
b. penetration is poor
c. Argon increase spatter levels
d. Poor cap profile or weld contour
ANS : B
26. Which of the following alloying elements can reduce the effect of ‘ temper brittleness’’ in steel when
operated at elevated temperature.
a. Nickel
b. Chromium
c. Vanadium
d. Molybdenum
ANS : D
27. In CO2 welding, which modes of transfer is the most suitable to be used in the vertical position
a. Globular
b. Axial spray
c. Dip or short circuiting
d. All of the above
ANS : B
28. Before use, electrodes classified as BS 639 : 1986 E 42 43 R 10 or AWS type E 6013 need to be:-
a. Dried for 1 hour at 45 0 C
b. Dried for 2 hour at above 120 0 C
c. No drying or what soever
d. Dried for 1 hour at 120 0 C max.
ANS: D
29. Which of the following defects would be likely to occur if the specified preheating temperatures are
not adhered to when carbon manganese steels:
a. Slag inclusion
b. Delay cracking or cold cracking
c. Lack of sidewall fusion
d. Surface porosity
ANS: B
30. The usual method of assessing the sensitivity of a radiograph is by means of: -
a. Dosimeter
b. Fluoroscope
c. Penetrameter
d. Multimeter
ANS: C
FINAL ASSESMENT MULTIPLE CHOICE QUESTION
CSWIP WELDING INSPECTOR COURSE
MFY OO4
ALL QUESTION TO BE ATTEMPTED
1. Which of the following defects would be likely to occur if the specified temperature are not adhered to
when welding carbon manganese steel:
a) Slag inclusion
b) Hydrogen cracking
c) Lack of sidewall fusion
d) Porosity
ANS: B
84 0f 9
2. Which of the following mechanical properties of a weld in carbon manganese steel is most affected, if the
heat input per unit length of weld is excessively high:
a) Elongation
b) Tensile strength
c) Hardness
d) Toughness (impact value )
3. You observe centerline cracking in a weld that has been made at one of five workstation, each making
similar components. Would you:
a) Impound all welding consumables
b) Report the occurrence to the higher authority
c) Stop all welding
d) Call for full NDT checks
ANS : B
4. Which of the following defects in unlikely to be found by visual inspection:
a) Linear misalignment
b) Undercut
c) Overlap
d) Linear slag inclusion
ANS: D
5. A 10 mm fillet weld has a nominal :
a) Throat dimension of 10 mm
b) Area of 10 mm
c) Leg length of 10 mm
d) All of the above
ANS: C
6. Which of the following welding processes uses a resistive heating system to aid weld metal deposition:
a) MMA ( Manual metal arc )
b) SAW ( submerged arc welding )
c) ESW ( Electroslag welding )
d) Resistance spot welding
ANS : C
7. A ‘stabilizer’ in stainless steel is used to prevent the risk of :
a) Hot cracking
b) Hydrogen cracking
c) Lamellar tearing
d) Weld decay ( knife line crack )
ANS: D
8. The output characteristics of TIG and Plasma TIG set are normally :
a) Constant potential
b) Flat characteristics
c) Drooping arc characteristics
d) Constant voltage
ANS : C
9.The shrinkage that take place at the right angle to the line of a welded joints is called:
a) Transverse
b) Angular
c) Bowing
d) Longitudinal
ANS : A
85 0f 9
10. The main function of the choke (inductance) in the MIG/MAG process will affect:
a) The globular transfer mode to be more smoother arc
b) Increasing of current rise to the molten metal of wire and reduce the spatter level in dip transfer
c) Deposition rate
d) Arc voltage
ANS : B
11. Which statement with regards to Open circuit voltage is true:
a) OCV is the voltage measured during welding
b) OCV is the input voltage to the power source
c) OCV value normally above 200 volts
d) OCV is the voltage without current flow
ANS: D
12. During GTAW process which of the following defect would you not expect to find:
a) Spatter
b) Undercut
c) Slag inclusion
d) Silica inclusion ( Ferritic steel )
e) A and C answers are correct
ANS: E
13. In SAW, which parameter give greater control for the depth of penetration on the welded material :
a) Voltage
b) Wire feed speed
c) Wire size
d) Current
ANS : D
14. The most common failure associated to the repeated load in service is :
a) Corrosion
b) Ductile failure
c) Brittle failure
d) Fatigue
ANS: D
15. The directions of shrinkage in welded joint are known as :
a) Angular,dioganal and intergranular
b) Transganular, agglomerated and longitudinal
c) Transverse , short transverse and longitudinal
d) Short circuit, buckling and distortion
ANS : C
16. Which type of electrode flux covering normally very suitable only for PA position or flat welding
position.
a) E 7016
b) E 6013
c) E 7024
d) E 6010
ANS: C
17. A brittle failure normally has the appearance of fracture surface with :
a) Rough and dull grey appearance
b) Smooth fracture with beach mark
c) A cup and cone shape
d) None of the above is correct
ANS: D
86 0f 9
18. Welding with higher heat input with carbon manganese steel may cause :
a) Higher strength of joint
b) Higher hardness value
c) Higher integrity
d) Higher distortion
ANS: D
19. Welding with lower heat input with carbon manganese steel may cause :
a) Higher ductility
b) Higher dilution
c) Higher distortion
d) Higher hardness
ANS: D
20. A centerline cracking has been observed in a MIG/MAG process with a spray transfer mode.This is most
likely to cause by :
a) High percentage of carbon dioxide mix with argon
b) The inductance value too high
c) The deoxidiser in the filler too high ( Mangganese )
d) Incorrect depth to width ratio bead profile
ANS : D
21. What type of alloying element need to be added in steel for ‘easy machining’:
a) Mangganese
b) Chromium
c) Sulphur
d) Silicon
ANS: C
22. In GMAW for carbon steel , change of gas from 5% Co2 in Argon with 1oo % Co2 will give effect on
the following :
a) Smoother weld profile with less spatter level
b) Convex profile bead
c) Concave profile
d) Deeper penetration
ANS: D
23. Which of the following causes would not influence delay cracking:
a) High carbon percentage
b) Grease and paint on the plate surface
c) Joint type
d) Cooper percentage used in electrode wire coating
ANS: D
24. When welding 28 mm thick carbon steel with GMAW ,what type of shielding gas would not normally
used.
a) 25 % CO2 in Argon
b) CO2
c) Argon
d) 5% CO2 in Argon
ANS: C
25. Which of the following is not the reason for the increase of HAZ cracking when welding carbon
manganese steels:
a) Fast cooling after welding
b) High manganese content
87 0f 9
c) High carbon content
d) None of the above
ANS: D
26. Heat treating steel consists of three basic steps. Which of the following is not the description of the basic
steps to heat treating:
a) Cooling the steel at specified temperature
b) Heating the steel at specified temperature
c) Maintaining the specified temperature for a certain period of time
d) Controlling the weld sequence during the fabrication to the lower stresses prior to heat treating
ANS: D
27. Welding changes the properties of solid steel through :
a) Changing the final appearance of the steel
b) Mechanical changes cause by rolling
c) Metallurgical effects as a results of micrograph
d) Heating and cooling cycles with a welding arc and weld metal deposited
ANS: D
28. Steels that have intentional addition of sulphur , lead or selenium to improve machinability :
a) are used for truck axles only
b) Can not be welded
c) Can develop liquation crack in the HAZ after welding
d) Do not require approved procedures to be welded
ANS: C
29. Chromium Molybdenum steels for high temperature service typically have their carbon content below
0.2 %. What other alloying element is added to this steel to create a stable steel at elevated temperature:
a) Nickel
b) Gold
c) Silver
d) Vanadium
ANS : D
30. When using GMAW process, straight argon may be successfully used as a shielding gas when welding
the following materials :
a) Steel and aluminium
b) Straight is never used
c) Aluminium
d) Steel
ANS: C
MULTIPLE – CHOICE QUESTION

MFY – 005
1. A weld is defined as the junction or the edges of members which are to be joined or have been joined
a) False
b) True
ANS: A
2. A discontinuity can best describe as :
a. a defect judged to possibly interfere with the fitness for purpose of the weld
b. Any observable disruption in the weld or the parent metal
88 0f 9
c. Meaning exactly the same thing as a defect
d. Discontinuous weld
ANS: B
3. If you welding in the HLO 45 position, the axis of the joint will be in what position
a. Flat
b. Horizontal
c. Inclined 45 and fixed
d. Overhead
ANS: C
4. Which of the following can result in a hard and brittle condition resulting from rapid cooling: -
a. Excessive spatter
b. Slag inclusion
c. Excessive weld metal
d. Arc strike
ANS: D
5. What term does not apply to a butt weld
a. throat
b. Toe
c. Leg size
d. Bevel angle
ANS: C
6. Contaminants that can cause porosity in a weld include:
a. Paint
b. Rust and mill scale
c. Oil and grease
d. All of the above
ANS: D
7. A discontinuity which appears as a void or inclusion of foreign materials in the weld and Heat
affected Zone of the parent metal would be :
a. Lamination
b. Incomplete fusion
c. Misalignment of the plates prior to joining
d. Nicks or gouges from plate preparation
ANS: B
8. If you were welding in the PC position you would be depositing weld from which direction
a. Vertically
b. Overhead
c. Flat
d. Horizontal
ANS: D
9. Which of the following would be considered the most serious structural discontinuity:
a. Slag inclusion
b. Crack
c. Lack of interun fusion
d. Sharp undercut
ANS: B
10. In manual welding applications, which of the following may cause porosity:
a. Incorrect electrode angle
b. Low current
c. Too high arc length
89 0f 9
d. All of the above
ANS: D
11. The effective or Nominal design throat thickness of a complete joint preparation butt weld is :
a. Considered to be equal to the thickness of the base metal less 3 mm
b. Considered to be equal to the thickness of the base metal thickness less 1 mm
c. Equal to the thickness of the base metal thickness
d. Equal to the thickness of the base metal thickness if welded from both sides
ANS: D
12. When weld metal at the toe of a fillet weld does not fuse completely to the base material the
resulting fault is referred to as:
a. Overlap
b. Concavity
c. Undercut
d. Convexcity
ANS: A
13. Excessively large root face on a weld joint preparations:
a. will result in excessive reinforcement
b. Can prevent penetration to the desired depth
c. Will result in excessive penetration
d. Is the primary cause to lack of fusion
ANS: B
14. Incomplete joint penetration can be defined as :
a. Improper joint preparation
b. Weld metal that does not extend through the full depth of the joint required by the design
c . Also known as lack of fusion
d . None of the above
ANS: B
15. Which of the following would contribute significantly to lack of fusion:
a. Heavy scale on the welded joint surface
b. Incorrect welding technique
c. Incorrect joint design
e. All of the above
ANS : D
16. If you were welding in PA position you would be depositing weld from which direction
a. above the joint
b. Vertically
c. Below the joint
d. Horizontally
ANS: A
17. Which of the following is not considered to cause incomplete fusion:-
a. using too large an electrode for a narrow vee
b. Using wrong type of electrode
c. Welding current exceeding that specified on a WPS
d. Improper manipulation of the electrode
ANS: C
18. Dimensional discontinuities become dimensional defects when :
a. their dimensional have found to exceed the set limits of a specification or code
b. there is no different since the terms mean the same
c. specified by the welding inspector
d. specified by the engineer
90 0f 9
ANS : A
19. Which term does not apply for fillet weld:
a. Actual throat
b. Toe
c. Included angle
d. Leg length
ANS: C
20 Defective mechanical properties of a weld does not include:
a. inadequate impact strength
b. Excessive distortion
c. Inadequate ductility
d. Excessive hardness
ANS: B
21. The main reasons using the least amount of consumable materials and to keep joint preparations to
minimum is :
a. smaller weld generally look better
b. Improve strength
c. Improve toughness of the weld metal
d. To reduce the cost and with less weld metal there is the possibility of fewer defects
ANS: D
22 . For plates of unequal thickness the effective throat thickness is :
a. equal to the thickness of the thinner plate
b. Equal to the thickness of the thinner plate plus 3 mm
c. Equal to the thickness of the thicker plate
d. Equal to the thickness of the thinner plate
ANS: A or D
23. The shortest distance measured from the root to the face of a fillet weld excluding weld
reinforcement is referred to as:
a. Included angle
b. Leg size
c. Weld reinforcement
d. Design throat
ANS: D
24. Select the correct term
a. Groove joint
b. Butt joint
c. Plug joint
d. fillet joint
ANS : B
25. Which of the following is not related to weld joint preparation or fit up :
a. bevel angle
b. Root face
c. root opening
d. leg size
ANS: D
26. Weld joints designed with J preparations are usually used only on very thick materials. Why?
a. J preparations afford limited access to the root of the joint
b. J preparations are more difficult to fit than other preparations
c. J preparations are expensive because they must usually be machined
91 0f 9
d. J preparations require the least amount of the filler metal for a given thickness
ANS : D
27. Failure to deposit weld metal to melt into the previous weld layer is most commonly referred to
as :
a. Internal undercut
b. Incomplete fusion
c. Excessive concavity
d. Lack of penetration
ANS: D
28. Which of the following could contribute to distortion:-
a. internal porosity
b. Incorrect weld pass sequence
c. Slag inclusion
d. Inadequate root face
ANS: B
29. If you weld in PE position you would be depositing weld from which direction:
a. above the joint
b. Horizontal
c. vertically
d. below the joint
ANS : D
30. Cold lapping is the term to indicate:
a. above the joint
b. Horizontal
c. vertically
d. below the joint
ANS: A
MULTIPLE – CHOICE QUESTION

MFY – 006
1. In FCAW and GMAW, for a given electrode diameter, as the amperage increased the wire speed will
a) Increase
b) Stay the same
c) Increase for GMAW and decrease for FCAW
d) Decrease
ANS: A
2. When using GMAW, welding of aluminium, the liner should be made of
a) Ceramic
b) Nylon
c) Cooper
d) Steel
ANS: B
3. Fluxes of SAW are generally name by the method of manufacturer such as :
a. Fused,agglomerated and mechanically types
b. Fused,agglomerated and granular types
c. Fused,ground and mechanically mixes types
92 0f 9
d. Granular,agglomerated and mechanically mixed types
ANS: C
4. In GTAW process an arc is formed between: -
a. No arc is present
b. The tungsten electrode and the work piece
c. The tungsten electrode and the filler metal rod
d. The filler rod and the work piece
ANS : B
5. In the Gas Tungsten Arc Welding process, gas shielding of the weld pool may be provided by which
gas(es) :
a. Carbon dioxide
b. Argon or Helium
c. Argon or Oxygen
d. Oxygen or Helium
ANS: B
6. Travel speed is the rate at which the welding gun progresses along the joint.As the travel speed is
increased:
a. The heat input of the joint increased
b. The heat input into the joint is decreased and the penetration is decreased
c. The penetration is increased
d. The penetration become increased and the weld bead becomes higher and wider
ANS: B
7. There are four methods used to initiate the arc in the Gas Tungsten Arc Welding ( GTAW) process.
Which method has the potential problem of contaminating the electrode and transferring tungsten to the
work piece :
a. Pulsed start method
b. High frequency start method
c. Scratch or touch start method
d. Pilot arc start method
ANS : C
8. The pulsed Gas Meta Arc Welding process is only suitable for flat welding position only
a. True
b. False
c. Vertical only
d. Flat and vertical
ANS: B
9. In Shielded Metal Arc welding the molten metal is protected by:
a. The molten metal is not protected
b. External carbon dioxide
c. Gases created from the composition of the electrode covering
d. External argon shielding gas
ANS: C
10. Electrodes for Shielded Metal Arc Welding (MMA) may be manufactured with any of three
different coating types, the three types are:
a. Basic ,normal and cellulose
b. Rutile, cellulose and basic
c. Rutile, basic and normal
d. Rutile , cellulose and normal
ANS: B
11. In general, the Gas Metal Arc Welding (GMAW) mode of transfer best suited for welding thin sheet
93 0f 9
is :
a. Spray
b. Globular Transfer
c. Should not use GMAW for welding thin sheet steel
d. Short circuiting transfer
ANS: D
12. The pulsed mode of transfer (GMAW) is a variation of the spray transfer mode that makes use of low
background current with a higher, rapidly pulsing current superimposed on it
a. True
b. False
ANS: A
13. In general, globular transfer has less spatter than spray transfer
a. False
b. True
ANS: A
14. The shielding gas that is commonly used in Flux Cored Arc Welding ( FCAW )
Process is:
a. Hydrogen
b. Carbon Dioxide
c. Helium
d. Argon
ANS: B
15. In general, the amount of oxygen in a mixed gas for use with Gas Metal Arc Welding (GMAW)
should be limited to:
a. Oxygen should never be used
b. 10% maximum
c. 2% maximum
d. 50% maximum
ANS: C
16. In Gas Metal Arc Welding and flux Cored Arc Welding, as the arc length decreases, the voltage
increases
a. False
b. True
ANS: A
17. When using the Gas Tungsten Arc Welding process for welding aluminium, the use of AC current is
recommended,as the half cycle where the electrode is positive provides a cathodic cleaning action to remove
oxide from the surface of the base metal: -
a. True
b. False
ANS : A
18. When using Gas Metal Arc Welding (GMAW) process, straight argon may be successfully used as a
shielding gas when welding the following material(s):
a. Aluminium
b. Steel or Aluminium
c. Steel
d. Straight argon is never used
ANS: A
19. The FCAW process may normally be used to weld the following material(s)
a. Low carbon steels and austenitic stainless steel
b. Aluminium and low carbon steel
94 0f 9
c. Aluminium
d. Copper and bronze
ANS : A
20. A 70 % duty cycle means that a machine may, at its rated output, run:-
a. One hour out of every seven hours
b. Seven minutes out of every ten minutes
c. Forty two minutes out of every one hour continuously
d. Seven minutes out of every hour
ANS: B
21. Three main modes of transfer in Gas Metal Arc Welding ( GMAW ) are:
a. High arc, globular and short circuiting
b. Spray, high arc and drooping
c. Spray,globular and drooping
d. Spray,globular and short circuting
ANS: D
22. In Gas Metal Arc Welding (GMAW), spray transfer may be achieved using shielding gases
containing
a. Less than 50% argon
b. 100% Carbon Dioxide
c. More than 85% Argon
d. Less than 75% Argon
ANS: C
23. The following gas(es) is (are) considered inert:
a. Helium and oxygen
b. Argon and Oxygen
c. Argon and helium
d. Carbon Dioxide
ANS: A
24. If the welding machine is operated at higher current than its output but still within the capacity of the
machine, the duty cycle must be increased
a.True
b.False
ANS: F
25. A constant current power source is suitable for the :
a. SMAW and GMAW
b. SMAW and SAW
c. FCAW and GTAW
d. GTAW and Plasma GTAW
ANS: D
26. The addition of deoxidizer, such as silicon and aluminium, to GMAW electrodes allows filler metal
to be used to weld steels that have a rusty or dirty surface ( although a sacrifice in weld quality is possible).
a.True
b.False
ANS : A
27. In CO2 welding, which modes of transfer is the most suitable to be used in the vertical position
a. Globular
b.Axial spray
c.Dip or short circuiting
d.All of the above
ANS: B
95 0f 9
28. Before use, electrodes classified as BS 639 : 1986 E 42 43 R 10 or AWS type E 6013 need to be:-
a.Dried for 1 hour at 45 0 C
b.Dried for 2 hour at above 120 0 C
c.No drying or what so ever
d.Dried for 1 hour at 120 0 C max.
ANS: D
29. Which of the following defects would be likely to occur if the specified preheating temperatures are
not adhered to when carbon manganese steels:
a. Slag inclusion
b. Delay cracking or cold cracking
c. Lack of sidewall fusion
d. Surface porosity
ANS: B
30. The usual method of assessing the sensitivity of a radiograph is by means of: -
a.Dosimeter
b.Fluoroscope
c.Penetrameter
d.Multimeter
ANS: C
MULTIPLE CHOICE QUESTION

CSWIP WELDING INSPECTOR COURSE
MFY 007
ALL QUESTION TO BE ATTEMPTED
1. Chromium molybdenum steels for high temperature service typically have their carbon content below
0.2% What other element is added to the steel to create a stable steel at elevated temperatures?
a. Vanadium
b. Selenium
c. Sulphur
d. Nickel
ANS : A
2. Which of the following could be used to prevent intercrystalline corrosion in Austenitic Stainless steel?
a. Vanadium
b. Selenium
c. Sulphur
d. Niobium
ANS: D
3 . Which of the following metals is most easily to be welded?
a. High strength steel
b. Stainless steel
c. Medium carbon steel
d. Mild steel
ANS: D
4 . Hydrogen trapped in the weldment can cause hydrogen cracking if the content of hydrogen is too high
What is the other name commonly used to describe hydrogen cracking?
a. Hot tears
b. Liquation cracking
c. Reheat cracking
d. Delay cracking
96 0f 9
ANS : D
5 . Which of the following is not a pattern that the atoms of steel arrange themselves in?
a. Body centered cubic
b. Body centered tetragonal
c. Face centered cubic
d. Diomond centered cubic
ANS: D
6. A hard and brittle microstructure in a low alloy steel can be improve its properties to soft and ductile by :
a. Increasing the heat input during welding
b. Must follow by post heating after welding
c. Hardening
d. Annealing
ANS : D
7. What happen to the properties of the steel when the carbon is increased to 0.6%?
a. Ductility increases
b. Weldability increases
c. Malleability in increases
d. Tensile strength increases
ANS: D
8. What is the affect will occur to a carbon manganese steel if the steel has been rapid cooled from
austenite region?
a. It becomes ductile
b. The toughness increases
c. Its hardness increases
d. Its yield strength decreases
ANS: C
9. Which of the following statements is true with regards to hydrogen cracking?
a. It is because of rapid cooling of weld metal and others factor
b. It is a hot type of crack
c. It only occur in the HAZ
d. Ductile grain structure is the most susceptible to hydrogen cracking
ANS: A
10. The arc energy during a welding process :
a. Does not effect the toughness of weldment
b. Must be high in order to avoid lack of fusion
c. Affects the width of HAZ
d. All of the above
ANS: C
11. In a martensitic grain structure what would you not expect to increase?
a. Strength
b. Hardness
c. Toughness
d. All of the above
ANS : C
12. Nitrogen and oxygen are considered to be important elements during the steel making process :
a. cause sulphur to isolate in the steel
b. cause imperfections if not removed in sufficient quantities
c. improve the quality of steel
d. Improve the surface appearance of the steel
ANS: A
97 0f 9
13. Sulphur is added to steel to improve:
a. Strength
b. Hardness
c. Toughness
d. Machine characteristic of the steel
ANS: D
14. Oxygen and sulphur in steels for a non metallic inclusion during the rolling process and can lead to what
after welding:
a. Sulphide precipitation
b. Oxygen rich welds
c. Lamellar tearing
d. Stress corrosion
ANS: C
15. Steel is an alloy composed mainly of :
a. coke and iron
b. magnesium and copper
c. carbon and chromium
d. iron and carbon
ANS: C
16. When weave technique the heat input using the same welding parameters (amps and voltage) as those
used for stringer bead will be:
a. Be the same as that for the stringer bead
b. Lower than that for the stringer bead
c. Will be higher than the stringer bead
d. Unaffected because technique has no influence on the heat input
ANS: C
17. Heat treating will:
a. improve the yield strength of the steel only
b. increase the elongation of the steel only
c. alter the chemical composition of the steel
d. not improve the properties of steel as a whole
ANS : C
18. The region of HAZ that gets heated to a temperature between 700 c and 900 c is called:
a. wide band HAZ
b. Tempered HAZ
c. Spherodised HAZ
d. Intercritical HAZ
ANS : D
19. The fully transformed HAZ located next to the fusion boundary in a weldment is the area:
a. Where cracking does not occur
b. Where cold cracks will not occur
c. With lowest tendency to form cold cracks
d. With the highest tendency to cold cracks
ANS: D
20. Martensite is a hard phase in steel and highly dependent on its properties from the amount of carbon
trapped in the Body Centered Cubic atom arrangement. When carbon is trapped in this atom arrangement to
cause the:
a. Carbon dissolves in this iron
b. Carbon atoms cause the BCC shape to distort resulting in increased hardness
c. Iron transforms to pig iron
98 0f 9
d. Carbon separates out to form isolated island martensite
ANS : B
21. Slowly cooled of mild carbon steels have a microstructure with:
a. High tensile strength
b. Lowest strength and the highest ductility
c. Highest strength with lowest toughness
d. Brittle structure
ANS : D
22. The ability of the alloy steel to form martensite can be determined by its :
a. Iron carbon diagram
b. equilibrium diagram
c. Carbon equivalent value
d. Transition curve diagram
ANS : A
23. The formation of hard and brittle grain structure in alloy steel can be controlled by :
a. Used of low arc energy
b. Increase the material thickness
c. Pre heating the material to welding
d. All of the above
ANS: C
24. The cooling rates of weldment is very critical where it can gives a formation of martensite or Bainite.
What factors that will influence the cooling rates?
a. Type of consumables and materials
b. Size of electrodes and welding position
c. Thickness, material size and thermal conductivity
d. All of the above
ANS: C
25. The main factors likely to cause lamellar tearing are thus:
a. Materials with lamination
b. Materials with greater thickness
c. Materials with high thermal conductivity
d. Low, short transverse ductility materials
ANS : A
26. The combination of iron and sulphur during welding will promotes :
a. Globular form of microstructure along the grain boundaries
b. Higher strength of the centre of weld metal
c. Low melting point along the grain boundaries
d. Higher hardness of weld metal compared to HAZ
ANS: C
27. The purpose of through thickness test is to determine:
e. the susceptibility of materials to hot cracking
f. the strength of through thickness of materials
g. the amount of energy absorb and toughness of materials
h. susceptibility of steel plate to lamellar tearing
ANS: B
28. Which following factor does not contribute to the formation of solidification cracking:
a. High dilution welding process
b. Low travel speed applied during welding
c. High sulphur materials
d. Fast travel speed
99 0f 9
ANS : D
29. Which of the following statement is correct for multi run welding compare to single passed welding:
a. High productivity can be produced with multi run
b. Higher distortion with multi run compare to single run
c. Higher energy absorbed and higher toughness with multi run
d. Multi run welding less cracking to occur
ANS: B
30. What alloying element that may helps on controlling of intercrystaline corrosion in austenitic stainless
steel
a. Molybdenum
b. Vanadium
c. Columbium (Niobium)
d. Cooper
ANS:
100 0f 9
101 0f 9

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1.

Which of the following butt-weld preparations is usually the most susceptible

2. What is the leg length of a fillet weld?

8. What is meant by the term weld junction?

1. Defects outside the permissible limits of the applicable specification should

10. The possible effects of having a travel speed too fast:

Multi – Choice Question Paper (MSR-WI-3)

1. The likelihood of a brittle fracture in steels will increase with:

Multi – Choice Question Paper (MSR-WI-4)

Welding Inspection, Steels – WIS 5

Assessment Question Paper (MSR-AWI-1 05)

1. Easy addition of additive

A. Statements 1 & 4 are correct

symbols gives the correct representation?

25. Austenitic stainless steel can be identified by:

62. Another name for Suckback in the root of a weld is:

(a) Weldability aspects

(a) H2 control is needed

(a) Have poor profile

206. In accordance with BS 499 what is the weld junction?

209. Which of the following is not a fusion welding process:

215. The welding arc could be characterized as:

(a) Hydrogen, moisture, martensite and heat

255. Which of the following could cause root concavity?

259. How many Mpa are equal to 1 N/mm2?

260. What is the UTS of a material?

265. Basic coated electrodes provided in standard packaging:

268. What is the purpose of a rectifier?

272. What is the leg length of a fillet weld?

276. Why have a high OCV with MMA welding?

280. What is a crater pipe?

281. Why is a weld procedure qualification test necessary?

284. Non-planar defects associated with a weld:

285. Lamellar tearing:

288. Which of the following would show as light indications on a radiograph?

1. Which of the following does not contribute to hydrogen cracking:

9. Crack Tip Open Displacement test is used to measure

27. An excessively large root face on a weld on a weld joint preparation:

FINAL ASSESMENT MULTIPLE – CHOICE QUESTION

14. Which is the compulsory part of an electrode classified to BS EN as

17. When approving procedure to BS EN 288 –3 the welder: -

19. Inverters are: -

24. Ultrasonics would be preferred over radiography due to:-

MULTIPLE – CHOICE QUESTION

MULTIPLE – CHOICE QUESTION

MULTIPLE CHOICE QUESTION

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