(d) Consumables for Submerged arc welding

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
(d) None of the above

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
(d) None of the above

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

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

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

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

116. Generally the most suitable method of detecting lack of side wall fusion would be:

(a) UT
(b) MPI

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 (c) RT
(d) PT

117. Hot shortness is a term used to indicate:

(a) Lamellar tearing

(b) Solidification cracking
(c) Hydrogen cracking
(d) None of the above

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
(d) None of the above

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
(d) All of the above

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

121. A welding inspector’s main attribute includes:

(a) Knowledge and experience

(b) Literacy
(c) Honesty and integrity
(d) All of the above

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
(d) All of the above

123. The correct terminology in the preceding question (7) is:

(a) -
(b) -
(c) -
(d) -

Page 17 of 43
124. 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
(d) All of the above

125. The correct term for “cap height” is:

(a) Reinforcement
(b) Cap profile height
(c) Excess weld metal
(d) All of the above

126. A tensile test will assess:

(a) Impact values

(b) Stress
(c) Strain
(d) Both B & C

127. 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

128. An austenitic stainless steel may suffer:

(a) Weld decay

(b) Sensitisation
(c) Solidification cracking
(d) All of the above

129. Carbon equivalent values are useful to determine:

(a) Weldability aspects

(b) Crack sensitivity aspects
(c) Typical mechanical properties
(d) All of the above

130. A basic electrode would normally:

(a) Have superior mechanical properties

(b) Require baking before use
(c) Not be used on low carbon steels
(d) Both A & B

131. When referring to TIG welding, the shielding gas could be:

(a) Argon + Hydrogen

Page 18 of 43
 (b) Argon + Helium
(c) Argon + Nitrogen
(d) All of the above

132. When referring to MIG welding, the shielding gas could be:

(a) Argon
(b) Argon + 1% oxygen
(c) Argon + 20% CO2
(d) None of the above

133. Submerged arc utilizes:

(a) Deep penetration characteristic

(b) High deposition rates on DC +
(c) Flat (PA) welding only
(d) None of the above

134. 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

135. The most serious defect types are:

(a) Planar
(b) Cracks
(c) Lack of fusion
(d) All of the above

136. 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

137. Which of the following discontinuities could be classified as a service induced discontinuity?

(a) Fatigue crack

(b) Porosity
(c) Machining tear
(d) Lap

138. Which of the following contamination could affect the sensitivity of penetrant?

(a) Acid
(b) Water
(c) Salts

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 (d) All of the above

139. 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

140. 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

141. 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

142. 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

143. 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

144. 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

145. 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

146. 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
(d) All of the above

147. 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

148. 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

149. 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
(d) All of the above

150. 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

151. 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

152. When welding a double V butt joint with SAW process the presence of centerline porosity may
be due to:

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 (a) Damp flux
(b) Contaminated joint preparation
(c) Incorrect stick out lengths
(d) All of the above

153. 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

154. 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

155. 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

156. 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

157. 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

158. 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

Page 22 of 43
159. Which of the following will vary the most, when varying the arc length?

(a) Voltage
(b) Amperage
(c) Polarity
(d) None of the above

160. 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

161. 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

162. 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

163. 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

164. 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

165. The HAZ of fusion weld:

(a) Usually has the highest tensile strength

(b) Cannot be avoided
(c) Is usually martensite

Page 23 of 43
 (d) Both A & B
(e) All of the above

166. Which of the following welding processes would you expect to use a collet:

(a) TIG / TAG

(b) MIG / MAG
(c) MMA
(d) All of the above

167. 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

168. 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

169. Which of the following processes use a constant 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

170. 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

171. What kind of steel is used for making filler rod?

(a) Killed steel

(b) Rimming steel
(c) Carbon steel

172. Which of the following is not related to weld?

(a)

Page 24 of 43
 (b)

(c)

173. Which of the following NDT method is not suitable to detect sub surface defect?

(a) UT
(b) PT
(c) RT
(d) MPI

174. SAW in single pass weld will give:

(a) Poor profile

(b) Burn rapidly
(c) Good penetration
(d) None of the above

175. 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

176. 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

177. What types of electrodes needs extra treatment?

Page 25 of 43
 (a) Basic
(b) Rutile
(c) Cellulosic

178. 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

179. 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

180. 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:

(a) Impound all welding consumables

(b) Report the occurrence to a higher authority
(c) Stop all welding
(d) Call for full NDT checks

181. Which of the following defects is unlikely to be found by visual inspection?

(a) Linear misalignment

(b) Undercut
(c) Overlap
(d) Linear slag inclusions

182. 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

183. 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

184. In MMA welding, what parameter is used to control the penetration into the base material?

Page 26 of 43
 (a) Voltage
(b) Welding speed
(c) Iron powder in the coasting
(d) Current

185. 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
(d) None of the above

186. What type of power source characteristic is required for manual welding?

(a) Constant voltage

(b) Flat characteristic
(c) Drooping Characteristic
(d) Motor generator

187. Which of the following destructive test would indicate the toughness of weld metal and parent
metal – HAZ?

(a) Macro
(b) Nick break
(c) Hardness
(d) Charpy vee notch

188. Degreasing components are essential for quality welding but some agents may:

(a) Cause corrosion problems

(b) Give off phosgene gas
(c) Leave residues
(d) All of the above

189. Which of the following chemical elements has the greater effect on the hardenability of a steel
plate?

(a) Molybdenum
(b) Chromium
(c) Titanium
(d) Carbon

190. 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

Page 27 of 43
191. 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

192. 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

193. 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

194. 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

195. 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

196. A steel described as QT will have improved tensile properties because it has:

(a) Had control of chemical composition

(b) Been heat treated
(c) Been quality tested
(d) Been vacuum melted

197. 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

198. In SAW, the use of excessively high voltage would result in:

Page 28 of 43
 (a) Insufficient flux melting
(b) Excessive flux melting
(c) Slag removal difficulties
(d) Spatter

199. 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

200. 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

201. 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

202. 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

203. 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

204. 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

205. In friction welding, is the metal at the interface in the:

Page 29 of 43
 (a) Liquid state
(b) Solid state
(c) Plastic state
(d) Elastic state

206. 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

207. 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)

208. 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

Page 30 of 43
 (d) The part of the weld, which undergoes metallurgical change due to heat from welding

209. 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

210. 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

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

(a) Thermit welding

(b) Electro slag welding
(c) Laser welding
(d) Friction welding

212. 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

213. Which of the following are essential variables for PWHT?

(a) Heating rate

(b) Temperature attained
(c) Cooling rate
(d) All of the above

214. Most metals expand when heated, the change in length is expressed as:

(a) Thermal conductivity

(b) Modulus of elasticity
(c) Coefficient
(d) Yielding

215. In TIG welding the nozzle is usually made:

Page 31 of 43
 (a) Copper
(b) Aluminum
(c) Ceramic
(d) Copper / Zinc

216. Which of the following is the odd out?

(a) Neon
(b) Xenon
(c) Argon
(d) Nitrogen

217. 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

218. 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

219. 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

220. 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
(d) Flux coverings, short electrode lengths and relationship between amps and volts

221. 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

Page 32 of 43
222. 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

223. Which sub atomic particle has a +ve charge?

(a) A proton
(b) A photon
(c) An electron
(d) A neutron

224. Which material is the most susceptible to reheat cracking?

(a) High carbon steel

(b) Killed steel
(c) Creep resistant steels
(d) Austenitic steels

225. 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

226. 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
(d) All of the above
(e) None of the above

227. 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

228. 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

Page 33 of 43
229. 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

230. 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

231. Which of the following materials has the poorest weldability?

(a) Austenitic stainless steel

(b) Martensitic stainless steel
(c) Carbon manganese steel
(d) HSLA steel

232. 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

233. Which of the following is an alternative name for a crater crack?

(a) Cold crack

(b) Tearing
(c) Star crack
(d) Fatigue crack

234. 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).

235. 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

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236. The weldability of a material may be affected by:

(a) Temperature of the component

(b) The Ceq % of the material
(c) The elements in the material
(d) All of the above

237. Which of the following heat treatment processes would be used for grain refinement?

(a) Annealing
(b) Normalizing
(c) Quenching
(d) H2 release

238. 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

239. 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

240. What is the possible cause of too mush 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

241. 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

242. 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

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 (b) Use pyrometer
(c) Use a vernier caliper
(d) Use a densitometer

243. Which of the following statements is true?

(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

244. Which of the following is not an inert gas at welding temperature?

(a) Argon
(b) Neon
(c) Carbon dioxide
(d) Helium

245. Which arc welding process uses a non consumable electrode?

(a) MIG
(b) TIG
(c) SAW
(d) None of the above

246. 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

247. 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

248. Which of the following statements is true?

(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

249. 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

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 (d) Weld defects, pearlite, hydrogen and a temperature above the melting point for the
material

250. How many temperature indicating crayons would be required to ensure the preheat temperature
was lying within a specified range?

(a) 1
(b) 2
(c) 3
(d) As many as possible

251. 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

252. 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
(d) All of the above

253. Which of the following is not a type of crack?

(a) Fissure
(b) Lamellar tear
(c) Fish eye
(d) Reheat crack

254. 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

255. 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
(d) All of the above

256. Which of the following standards is entitled imperfections in Metallic fusion welds with
explanation:

(a) BS EN 25817
(b) BS EN 26520

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 (c) BS EN 22553
(d) BS EN 24165

257. 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

258. High Phosphorous contents in carbon steels may cause:

(a) Cold shortness

(b) Hot shortness
(c) An increase in ductility
(d) An increase in malleability

259. If arc strikes are found on carbon steel (C eq of .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

260. 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

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

(a) 144.9
(b) 25.4
(c) 14.7
(d) 1.

262. 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

263. 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

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264. What is a Vickers Pyramidal Indentor used for?

(a) To measure indentation toughness

(b) To measure ductility
(c) To measure hardness
(d) All of the above

265. What is the main constituent of a rutitle electrode flux?

(a) Cellulosic
(b) Titanium dioxide
(c) Calcium carbonate
(d) Asbestos

266. What does the 70 represent on a E 7010 AWS classified electrode?

(a) 70 N/mm2 minimum uts

(b) 70 N/mm2 minimum impact strength
(c) 70,000 psi minimum uts
(d) 70,000 psi minimum impact strength

267. 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

268. Sodium silicate in an MMA electrode flux:

(a) Stabilizes the arc

(b) Binds the ingredients of the flux
(c) Forms slag
(d) All of the above

269. 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

270. 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

271. A welding process using equipment with a flat characteristic:

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 (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.

272. 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

273. 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
(d) It is not possible to induce lack of side wall fusion during MMA welding

274. 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

275. 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

276. Which of the following will vary the most when varying the arc length using the MMA
process?

(a) Voltage
(b) Amperage
(c) Polarity
(d) None of the above

277. 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

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 (d) All of the above

278. 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

279. 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

280. 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
(d) All of the above

281. 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
(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

282. 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

283. 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

284. 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

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 (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

285. 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
(d) All of the above

286. 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

287. 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
(d) All of the above

288. Cold lapping is another term for:

(a) Lack of fusion at the toe of a weld

(b) Low amperage
(c) Undercut
(d) Hydrogen cracking

289. 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

290. 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

291. Which of the following welding processes does not use a consumable electrode?

(a) SAW
(b) MMA
(c) TIG
(d) ESW

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292. The hardest grain structure capable of being produced when welding C/Mn steel is:

(a) Bainite
(b) Austenite
(c) Pearlite
(d) Martensite

293. 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

294. 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

295. 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
(d) All of the above

296. When welding a double V butt with the SAW process the presence of center line porosity may
be due to:

(a) Damp flux

(b) Incomplete penetration
(c) Contaminated weld preparation
(d) Atmospheric contamination

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