PROGRAM TRAINING & EXAMINATION 2003 = \ |Requirement for candidates 1 Encoiment Farm 2 Curiculum Vitae 3 Examination Form 4 Eye Certiicate 5 2 photo's 4x6 {Method of Payment: 1 The confirmation fee (8¢%) after we received the erroment form 2. Payment ful amount sheuld be transferred not later than fest day 3. Allfees shoula be ransterred to PPT. Surveyor Indonesia USD Account No. 103268532 Ctibank Cab. Landmark, Rupiah Acc No. 1220038137816 Bank Mandi EXBDN Wisma indecemert (se updated USD exchange rate) ~ e Car Oy aa se spuies oh ee Feo _| CRWPIBGAS | Ach Pon ieely 2-8 Sancary ual Wieding rapestor bs Nakane TS 50600 SA January orcs toe lwass baker Uso 940.50) uso 43450 13-24 Jaruay Prac. Utrasonic Inspection INove Jakarta — | usD4.ta400] usD507.10) usoso7.1o| usp 600.00 27-31 January _|Raclographe interpretation Iworze satan ‘Usb 883.50) USD 06 a0 usp 367.50 “07 February fPract. Penetrare inspection Inots0°e —|aatam sp 766,70) usD 39490] sD 304,90) USD 44339 17-21 February lasting Pataing 23 Jarces pata uso 1.038,0] Usb 502.79 Jee 28 February |wveder Certeation Batam 7-22 February sie sont lwass Sater usp eaoso| usp 434.50 ' [08 Maren” (teu Viskng inspector ova Jsuabeye | USD 508,00 | 10-15 March ie sen lwiss Isuabaye | USD 840.30] sD 434.50 le 28 March Pract. Penetantnepection INoTsoPE — |surabaya | sO 768,70) uso 304.60] uso 204,90] uso 442.39 [st waren «04 kent [pact Magnet Pate Inspection |NDTSOME — |Pakanbary | USD 768.70) usb 35480] USD 284-80] USD 44339 254 RadigrapneIterpretaton INor2s—eaxanbaru | sD es0'60) Usb 304 80 uso 367 59 2s 30 apn Welder Cecttcaton Paxanbars los - 03 May Miva Welding fspector ors satipanan | uso-sog oo 9-25 may mae te bass lsatipspan | usps4050} usD434 50 230 May Prac. tasan inepection Iwore Batkpepan | sO 1.14400] Usp s07.10] usoso7.1o] uso 0.00 02-08 sine lRaiographi meroretation INovzs [Jakarta ‘Uso 253.0] Uso 309.0] USO 367,59 16. 20 June rac Magnetic Parle Ispecton |NOTIOWE —|takarta USD 766,70] Uso 384.80] usD.294.90) USD 443,39 6 20 ne Biasting / Painting 20 jarces dakar. | uso 1035.10) uso 50270 227 lune Pract Penetrat rspecton INoT30rE [Jakarta ‘Uso 768.70) USO 354.20] UsD204,90) usp 449,30 227 ine lWetser Gariteaton akan [30 June - 11 July Pract Urssome inspection Inors Batam Usp 1.44.00) uso so7.1o] uso sor.10] uso e00.o| os 05a [Visual Weldng Inspector 073, Batem sD 500.09 lo7- 12 1uy ret ae \wiss Batam USD §40'50] uso 43450 ta 25 sy ay Curent Inspection Iworste Batam uso 1 925.09 77-08 August [sul Welsng Inspector ors suataya | USO 08,00] 5: 23 august | Weider Certcation Surabaya los05 September |vieua Wang Inspector lors, Pakartara | uso sogoa! 22-27 September fisesn sc wis Pakantars | USD 840.50] USD 43450 [28 Sep-3.0ct —|Radographc Imerpretaton INorze ——fatanbaru | UsDes0.60) uso 406 eo Usp 257,80 17 Oetover Basing! Painting 23 larces ——eatepapan | usp 1035.10] usp 592.70 31 October [Pract Ukrasoric Inspection ors Basypapan | uso 1.14400] uso 507,10] usDso7.zq] uso 600,09 [27-31 October | elder Cartation Batkpapan 08 Neverber —|Visual Welding Inspector ora lskane uso 606 oo L1SNovember fone sees miss Makara uso 9400) _usb 434,50 17-21 Noverber — [Radographic interpretation INTs [Jakarta sD a53.60] USD 3069 ‘uso 357,50 Jos- 05 December [Pract Magnetic Parice Inepection |NOTSOME {Batam us 768,70] USO 394/80) uso 304.00] USD 449,39 8-12 December [Pract Penetrant inspection INoTsOPE Batam {uso 789,70] USO 36400] USO 394,20] USD 443'30 MU A Sipfemtur.IW Training & Certification (S.E Asia) Sdn. Bhd No 8, Jalan TSb 10 /S9, Butoh Industrial Park {47000 So. Buloh * Selangor, Malaysia Tet No.600097382083 ‘Email : twisea@imnet my ESSENTIAL DOCUMENTATION PLEASE TICK EACH APPLICABLE BOX AND SIGN THE DECLARATION AT THE BOTTOM OF THIS SECTION Fax No.'603-6572378 Please note that our application cannot be processed without the following data: General documentation required from everyone Payment or comes Q Trang record (erent 2G4S-CSi) a ‘wo passport phates wih your rae cary pes conte tack pease corel sagle fern a Yen contest (ecepturcnraterinegecon) a 5. Proce specication (Poste Welter and GRP Beoder Oty) a 6. tinea Cenfeaie (Unsaster essai en to ta produced en ta day of oxen, a 1. Personal details (please PRINT) Naren sy emarert 23s ‘Ades er comespencence itera rm ove) res Curent Cantczatis| scsi o G 9 a Q a ten ce No. EXO? doe 1an5 For office use only 8 Deforateverkom scheme maragemen(fecpiy hasbeen extencesy =] and understood the cocumentation issued bythe scheme management 'srelevani othe examination forwhich 12m applying and decar that! meet {he appropriate requrements, ‘accept responsiblity for any examination fees nthe event of nonpayment by the 1d that any appeal against an exam result must be received within sie exam date, ‘nave read the sting and include a the roqueted information. ‘understand that any ase statement may recut inthe examination being Invalisatee Sine Dele an | Stouts preteran examnaicn a week sonmancig Sree i ib bet 6 mato nparanen, bene Bengio distorts) Venue Jatero) Baum] Other Pease speci 5. Ultrasonic Welds Piste Nowe O Aerospace 5 Hatora & ConganertsC} Hota Comp & Sruces (3 Pe Node to Cuca sig C) 6. Radiography Welds Aerospace eaerat 8 Components o Ch Waser Comporers& Swuctwes Gammassy dence metal [] Welds oO Welds nee a Radiographic Interpretation Fencus 2} tsinbss["] Aluminum] Coeger 8 alos} Basic Radiation Safety [5] Radiation Protection Supervisor (3) 7. Eddy current Cote erexaminaten (01 CSHAP Yiekig inspec ony) 8. Underwater inspection au ws aw Coneie ‘fo Pasties ‘Sponsor (please PRINT) ee O rag iG i peo ppt) P32 Pra #11. Bonding fee Somme te | spec hor ras £ Feat co a ———Enaiaaies “ye anes Soatnge i es fase ton to) _— Poet: —_ 412.EWF Diploma i Z aut Tectrott C) enpoeer 2) Payment and method mo 20 30 10 Pe se dei We nead to hnow anat ronlesye yas hae ‘atfeaions ond Certfestesaetady taDUE TO H2 LESS SOLUBILITY AND WILL, WANT TO DIFFUSE TO THE HAZ, THIS OCCURS RAPIDLY AS DiFFUSSION INCREASED WITH HIGH TEMP. DGN SUATU GREAT INTERNAL STRESS, OCCURRING IN MICRO STRUC, WHICH IS VERY BRITTLE. ® CRACK MAY OCCUR AT AREAS OF HIGH STRESS: CONCENTRATION ‘TOE, SURFACE DEFECT DI WELD METAL wm Lyte C24 ub fet ae & > 13h SOL: CRACKING IBAT > HIGH SULPHUR CONTENT > DURING SOLIDIFIACTION MELTING POINT LEMAH BOUNDARIES | | hy riCATION (HOT SHORTNESS ~ SIFAT |» DEEP NARROW WELD > FeS PRODUCE LOW HOT » Fe8 PRODUCE LIQUID FILM ALONG THE GRATN * ~~ AKIBAT. > > SHORT TRANSVERSE. DIRECTION STRESS > LQUALITY MAT: ADA UNSUR SULPHIDES & CILICATES WILL. PRODUCE LOW THROUGH THK DUCT > PRESSURE OF H2, INCREASE THE CRACK PROPAGATION > HRESTRAIN IN JOINT~ H CONTRACTION STRESS TYPE, > STEPPED LIKE CRACK LOCATION, » JUST BELOW/ BENEATH THE HAZ IN AHORIZ PLANE > PARENT MAT. OTHERS. > TERIADI HANYA PADA THK MAT 7 ARIBAT; ¥ TERIADIDI SIS 304 > apANyAUNsTAPLE | “% AUSTENITIS 3/8 de vsy > CHROMIUM AFFINITY TO CARBON cae > AT 600850 TER JAD SINTESING Cr23¢6~ PRESENT LOSS OF CORROSION - WILL CAUSE "KNIFE LINE RAL ' Gar Hype wa Pe pals Df past re FLO hac Fans Cox hercs >| Pa 43016 Bo ue febiibe lle Lf poms Pot MEO hat ays 1% thle ple ie lA i~~ E22 /Q@LD CRACKING SOL, wICATION /HOT ‘LAMELEAR TearING [| DELAY eee CRACKING (laze: +S < 0.06% + BUITERING | + ADDED STABILISER ~ 100 GRM FC“ 0.1% CHANGE THE JOINT MIOBIOM AND TITANIUM y HARDNESS » 350 VPN DESIGN + LOW CARBON E 316 L. + STRASSES > 05 YS + USE FORGING / CASTING * LOW HEAT INPUT TEMP = 300 BSW * CONTROL THE INTERPASS. y MINMISE RESTRAIN PROPER DESIGN © PUY SOFT WIRE.TO y» SOLVENT ANNEAL r LOW HD DEPT & WIDTH MINIMIZE RESTRAIN, TREATMENT CONTROL. + CONTROIL, | | SULPHUR =0.007% OR H | QUALITY MAT | B STABILISE S/S 321, 347 7 USE*Z" TYPE, STRAP 20% - TRENGTH 2 REDUCTION IF USE LOW HEL. HAVE TO BAKED. (KAKED = a __DIBAKAR SAMPAI MATENG_ i i MAT,+ LOPERATOR SKILL ry APLICABLE TO NON MAGNETIC MAT. + LOW COST AMPLE, CHEAP & EASY TO. INTERPRET y PORTABILITY NOT REQD ELECT NEED SURFACE PREP 7 SURFACE BREAKING FLAWS ONLY » NOTFOR POROUS MAT + NOT PERMANENT j RECORD + POST CLEANING REQD PRE CLEAN NOT AS CRITICAL PT WILL DETECT SOME SUB SURFACE RELATIVEY LOW cost SIMPLE TO USE SIMPLE EQu/?” RAPID RESULT POSSIBLE TO INSPECT THROUGH THIN COATINGS DETECT LACK OF SIDEWALL FUSION + FERROUS & NON FEROUS ¥ ABLE TO DETECT THROUGH WALL THK + ABLE TO DETECT DEPT OF DEFECT KEY POINT? | __WORD PERMANENT RECORD + MOST MAT CAN BE TESTED * GIVES ADIRECT | IMAGE OF FLAWS FERROMAGNETI | MATERIAL ONLY DEMAGNETISM MAY BE REQ'D DIRECT CURRENT FLAW MAY PRODUCE ARC STRIKES NO PERMANENT RECORD REQ’D TEST 2 DIRECTION ry HIGH OPERATOR SKILL + DIFFICULT TO INTERPRET + REQUIRES CALIBRATION + SKILLED — INTERPRET REQ’D + POSSIBLE TO MISS PLANAR DEFECT + HEALTH HAZARD COSTLY SLOW RESULT — | NEED FILM PROCESS |SIZE > MINI -8 TYPE& CONDITION BASIC BAKED AT 350 OVER 1 HOUR, HOLD IN OVEN 150, QUIVER 70-80¢ RUTILE DRIED AT MAX 120 C. CELLULOSE BAKED OR WHATSOEVER ~ DEEP PENETRATION ~ STOVE PIPE LINE. NEVER, + FLUX TYPE - RUTILE~CO2 - CELLULOSE -H2 - BASIC -CO2 - Ar - He + SIZE > MIN20 ® MAX32 + TYPE: AS PER MANUF ry COND: STORE AT DRY PLACE KEEP INSIDE ON THE ORIGINAL CONTAINER + GASES SHIELDING TYPE: asia GIONISAS1~ NEED HIGH ARC VOLTAGE ~ Ar + He2% FOR S/S MIG’ MAG METAL INERT / ACTIVE + SIZE > MINOS >» MAX 16 + TYPE: ASPER MANUF * COND: STORE AT DRY PLACE KEEP INSIDE ON THE ORIGINAL CONTAINER + GAS TYPE: a, MIG: - Ar - He - Ar+He oe MAG: - coz - Ar+CO2- for SS - Ar85%+CO2 - lack of spatter. TYPE: ASPER MANUF COND: STORE AT DRY PLACE KEEP INSIDE ON THE ORIGINAL CONTAINER, FLUX TYPE: FUSED Flucky & shiny appearance. G re-cyling, H moisture resistance L impact properties AGLOMERATED Granular appearance. ‘Need to barried 400 C = hour G impact properties Y POINT WORD i }~ MMA H2 CRACK LACK 0 ROOT F POROSITY * ARC STRIKES uc + CRATER PIPE SILICA INL— FERITE STEEL + TUNGSTEN INCL + WELD ROOT OXIDATION ¥ POROSITY y ALLPOSITION |» HWg QUALITY + PORTABLE + WELD THIN PLAT + GRESTRICTED + NO SLAG ~CLEAN ACCESS. + PORTABLE + VERSATILE - + VERSATILE SERBA GUNA * CAN BE + EASY TO AUTOMATISATIO. OPERATE, N + CHEAP Wg Eq DISADVANTAGES —__ 7 LOW PRODY H SKILL WELDER H COST, IF THICK FUMES OVEN - LOW H2 + LOWPROD'Y + BTHKMAT + HFREQSTART— ELECT PROBLEM * 03 PROBLEM ~ MIG/ MAG METAL INERT / ACTIVE GA 7 SILICA INCLUSI + SOLIDIFICAT cry 7 CRATERPIPE || + BURN THROUGH | + COPPER INL | + LACKOSIDEWF | + POROSITY | + UC | * HPROD'Y + ALL POSITION + CHOICE MODE TRANSFER + THIN& THK » CAN BE MECH’N + SHOP Wg ONLY + HFUMES & 03 + CANNOT BEIN RESTRICT AREA + NEED PROPER PROTEC + EXPENSIVE + NEEDGA: WG COMPLEX MACH SOLIDIFICATION cR SHRINKAGE CAVITIES BURN THROUGH OVERLAP SLAG INCL POROSITY ure HPROD’Y SMOOTH W PROFILE THK MAT CAN BE MECH'N SAFE FOR EYES RECYCLING FLUX LIMITED W’g POS HHEAT INPUT B FOR THIN MAT ELECT SHOCK BULKY W’g MACHINE EXPENSIVE HOT EFFECT “RE! Y POINT: WORDMMA POWER SOURC! CONSTANT CURRENT (DROOPING) + POLARITY TYPE: - DC + (STRAIGHT) ~ DC~(REVERSE} | = ac (ROOPING) + POLARITY TYPE: - DC + (STRAIGHT) - DC~(REVERSE) - ac + TUNGSTEN TYPE: - THORIATED~ CANCER - CIRCONIATED - FOR AL& Mn - CERIATED =DcC) - LATHANUM + TORCH TYPE: ~ AIR & WATER COOLED + START TYPE: - SCRATCH, LIFT-UP & HFREQSTART STEEL “MIG / MAG METAL INERT / AC 7 POWER SOURCE: - CONSTANT - VOLTAGES (FLAT) + POLARITY TYPE: - DC+ (STRAIGHT) DESY PENET + TRANSFER MODES: = Dip transfer or short circuit 20~ 200 amp, for thin mat - Spray transfer ~ H current and H Voltage FOR THICK MAT| - Globular transfer - Pulsed transfer Sinergic Wg machine — rectifier ~ G fusion, less distorsion, low heat input » TORCH TYPE: - AIR & WATER _COOLED. "ry POWER SOURCI >» MINS > MAX250 + TYPE: ASPER MANUF €: MOD CLEAN + SIZE >» MINLO >» MAX 12.0 r TYPE: AS PER MANUF + Ci ABS CLEAN | + SIZE » MINOS >» MAX 50.0 y TYPE: ASPER MANUF + €:MODCL CONSTANT VOLTAG! > 1000 AMP AND CONSTANT CURRENT = 1000 AMP. » POLARITY TYPE: - DC+ (STRAIGHT) - v > MAX 150 + TYPE: ASPER MANUF _C: MOD CLEAN KEY POINT / WORD MIG / MAG — SPRAY ‘TRANSFER ~MAKE WELD OF A LOW BACK GROUND CURRENT WITH HIGHER RAPIDLY & PULSING CURRENT SUPER IMPOSED SAW ADA ARC BLOW. PERLL TANDEMVOLTAGE T. SPEED POLARITY SEBELUM MA GAS FLOW RATE + LAIN NYA SAMA MMA MIG/ MAG METAL INERT) ACTIVE ? GAS - ARC STICK-OUT LENGTH NOZZLE TO WORK DISTANCE GAS FLOW RATE WIRE FEED. SPEED. LINER LAIN NYA SAMA | MMA : KEY POINT WoRD ANGLE OF ELECT — FLUX DEPTH y ARC STICK-OUT LENGTH + NOZZLE TO WORK DISTANCE + LAIN NYA SAMA MMASone ~ \ a as 5 ; a a Sell > Wa nahh LD Vated prove Hee meat Copiontana. ? ae " fhe Mar dew. 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Stew) Car. 1 te foer | Aetronce choreWelding Inspection General Theory (Multichoice) Paper Wi-1 ‘This column is for official use only Name Results Signed Marker 1 Date Marker 2 | 1 Mnaceordance with BS 499 what is the weld junction” a The area containing HAZ and weld metal b. ‘The weld metal and parent metal 67 The boundary between the fission zone und [A\ The part of the weld, which undergoes metallurgical, chanyyddue to heat tiorn welding 2 Which of the following are essential facyéy for lander tearing? av High cesidual stresses, poor througf{thjckness dyctility, existing plate Jaminations. \ b. Poor through thickness ductility/ filligh face payallel with rolled direAioh of pave \ plate, most commonly occurs if butlwelds. | ©. Stress, poor through thickness/ductilit in face pagallel with rolled directivn of | parent material / \ d_ Tensile stress, deosidised paly/ plate [poor through ea 3 The strength of a fillet weld is\eimbry ofntratteft by de i) } a, Leg length | ( bo Weld fice A oY Throat thickfes) 7 \ d Allatthe affove \ 4. Which of the fol a Thermit weldikg 2 sion welding process7—. v b. Electro slay weld cc. Laser welding d Friction welding10, Name the fourth weld process crack which has a totally different formation mechanism to HICC, solidification cracking and lamellar tearing, 4 Liquiation cracking bY Re heat cracking © Crater cracking 4, Hot tearing Which of the following may described as @ Lack of root fusion b. Undercut. © Slag inclusions All of the above, Which of the following welding processes is not classed as un are welding process’ a. Blectroslay welding b/ Thermit welding Plasma welding 4. Botha and b. © All ofthe above Which of the following materials has the poorest weldability? ad Austenitic staintess steel b Martensitic stainless steel ¢. Carbon menganese steel d HSLA steel Ina fusion weld, which usually bis she highest tensile strength? a Weld meta! Parent material cr Heat affected zone d. Fusion zone Accrater crack may also be described as a Cold crack b. Tearing es Star crack d. Fatigue crackju Daie 2904 2 Which of the following welds would most likely be used in a situation where wo plates are to be joined that overlap (with no access on either side)? ar A plug weld b. A fillet weld. © A single-bevel buts weld dA single-vee butt weld, Which material is the most susceptible to re heat crackin? af High carbon steels b. Killed steels ©. Creep resistant steels d. Austenitic steels. Three essential factors for producing a fusion weld are; Melting, the cemoval of suttace oxide from the joint surfaces and elimination of atmosphere from th: Namie the fourth? on ot ths: are a The weld must be five fiom stress bo The filler material must match dat of the Parent material, of The completed joint must at least match the mechanical properties requiced Ly the specification d. An are for a heat source. Which are welding process/technique is likely to be used to repair localised porosity in a weld? MMA, PG position Mechanised arc weld Sub Arc. All of the above ed None of the above A welder qualified in the PG position would normally be quitlitied for weldiv a All diameters of pipe b. Welding positions PA, PC, PG, and Pl c In position PG only a All pipe wail thicknessDats 2901 20 se 16. Which of the following are considered to be heat affected zone cracks? a, Solidification cracks, lamellar tearing and reheat cracks b. Reheat cracks, liquation cracks and solidification cracks ¢. Hydrogen cracks, solidification cracks and liquation cracks dy Re heat cracks, liquation eracks and hydrogen cracks. 17. Which of the following, in MMA welding, is most likely to be caused by poor welder technique? a Hydrogen cracks bY Deep craters/crater cracks. Plate laminations. 4. Copper inclusions 18. In general it is not easy to mechanise the MMA weldiny process because a Short electrode lenyths, the eoutrat of the are lengtls and the praicess uses a flat characteristic b. Short electrode lengths, the contiol of the are cd The contro! of the ate Le d. Flux coverings, short electrode lengths and the relativaship between amps and volts igth and lus coverings sth, stop start problems and stwiet electiode len 19. Which of the following statements is true? a! Oxygen-fuel-gas cutting is essentially an oxidisation thermal eutting provess b. Oxygen-fuel-gas cutting is essentially a melting process The only fel gas used is acetylene 4, Propane is the preferred fixel flame as in oxygen-fiu it produces a hotter 20. A semi-automatic welding process is best described as’ 7a, The welder is responsible for the are gap and travel speed The welder is responsible for the travel speed only. ©. The welding plant controls botk travel speed and are gap but under constant supervision d. The welding plant controls botl travel speed and are gap, no supervision required2 24, The welding arc could be characterised as: a A high current, low voliage are with a flow of electrons flowing trom cathode to anode. b. A low current, high voltage arc with a flow of electrons flowing from cathode to anode © Amedium current and medium voltage with a flow of electrons and #ve ions Hlowine 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 tu anode. Which of the following standards is entitled Imperfections in Metillic Puston: Wekls with Explanation? a/ BS EN 25817. b. BS EN 26520, c&. BS EN 22553. d. BS EN 24165 Root concavity may be caused by which of the follow a. Excessive back purge pressure and very high heat inputs b. Excessive back purge pressure and entrapped yas. ©. Excessive root grinding and a slow travel speed d/ Excessive root grinding and excessive back purge pressure High phosphorous contents in carbon steels may cause ad Cold shortness b Hot shortness © An increase in ductitity d An iner ase in malleability Uare strikes are found on carbon steel (carbon equivalent of 0.59), what undesirable grain structure may be present? a Perlite b+ Martensite cc Bainite d. All of the above are undesirable grain structures in constructional steels| Candidaie _— SY/DUL DIVO ] FINAL ASSESMENT MULTIPLE ~ CHOICE QUESTION | x (00 CSWIP 3.1 WELDING INSPECTOR COURSE e. MFY - 001 ALL QUESTIONS TO BE ATTEMPTED, EXAMINATION TIME : 30 MINUTES Which of the following does not contribute to hydrogen cracking: a, External forces on the weldment b. Amount of hydrogen in the weld ~ ¢. Residual stresses in the weld @ Size and length of tinear discontinuities Pr For the are 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 V/€) Supplied through air ports in the electrode holder and directed along the electrode d. Supplied by another torch also by other operator . Acetylene hoses are distinctly difference from oxygen hoses .Why? A Because the internal diameters of the two are different < : B Because of operating pressure differences between fuel gas and oxygen < ©. Acetylene attacks the materials used in oxygen hoses @® To prevent accidental interchangeY Which of the following can result in a hard nd brittle condition resulting from rapid cooling: ee 7 @are strikes B. Excessive weld reinforcement ¢. Excessive spatter 4. Slag inclusion S. DC negative when used for MIG/MAG can give smooth arc. A. True (@B False In which of the following process is the use of pressure required to successfully joint the materials: TG B. MMA. SAW Stud welding %7. Which of the following will contribute significantly to lack of fusion . CA iocorrect joint design v B. Incorrect welding technique ¢. Heavy scale on the joint surface ~ "All of the above% Which of the welding process used loose grat A. FCAW (@saw < GTAW d. SMAW 9. Crack Tip Open Displacement test is used to measure A. Strength of the material being tested B. Hardness of the material < ‘he toughness of the materials, resistance to crack extension and the ‘acceptable flaw size all 4d. Ductility of the material being tested 0. 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 AG) True X11. The iron carbon diagram is used by metallurgists and others (o see how: a. Adding nickel changes the corrosion resistance of steels Adding carbon changes the response of the steel to temperature thanges x 4 c. adding molybdenum increases the toughness of steel d. adding chro improves corr:29. Which of the following defects would be likely to occur if the specified reheating temperatures are not adhered to when carbon manganese steels: — sere =~ a. Slag inclusion ® Delay cracking or cold cracking c. Lack of sidewall d. Surface porosity ‘The usual method of assessing the sensitivity of a radiograph is by means of: - a. Dosimeter b. Fluoroscope Penetrameter d. Multimeter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 Assist in the development of the penetrant indication from a defect d. Assist in the drying of the penetrant Overlap in a fillet weld would occur : 4, At some point in the weld throat b. only on the face of the weld @©At the toe of the weld d. At the root of the weld In the TIG welding process, gas shielding of the weld pool maybe provided by which gas (es ) a. carbon dioxide b. argon and oxygen (©argon and helium d. oxygen and helium Welding fux : - a. Helps on control the temperature of the pieces being welded b. Crates a temporary bond between the pieces being welded >) Protects from the atmosphere and removes the oxide film on the surface €. Makes it easier to move the electrodeIncreasing the carbon content of steel allows a given level of hardness to be achieved : a. at a higher cooling rate x without consideration of the cooling rate ¢. without adding chromium to the steel vv, @ At lower cooling rate M7. Which is Got a facto? that should be considered in selecting the best shielding gas mixture for a given application: See a. weld appearance and acceptable spatter level b. thickness,joint design and penetration requirements © the welder’s personal requirements d. Transfer mode A8. Which of the following is not considered to be cause of incomplete fusion a. Welding current exceeding that specified on a WPS + © Using too large an electrode for a narrow Vee < ¢. Improper manipulation of the electrode “a Using the wrong type of electrode < 719, Which is an advantage of an argon/hydrogen gas mixture in TIG of stainless steel eee a. Lower heat input 2 Improved toughness ~ 49 Faster travel speed d. Improved mechanical properties X20. 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 :- 4. The core wire offer lower resistance to the passage of the welding current 0. The manufacturer can more conveniently inclugAlloying elpments in the covering than produce special core wires (__ ¢. Both for reasons a and b above e. For some reason not listed above MAA. Sulphur is som es added to steel to improve: a. Th pact properties of the welded joint b. Provide hii er impurities levels c. Toughness of the parent materials (@ Machining properties characteristics of the steel — _— Co s yw cooling of liquid metal from high temperature promotes the growth of : a. Medium grains @ Large grains + Small grains d. A combinations of large and small grain4 22. 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 ¢. Any type of weld flaw A discontinuity judged to possibility interfere with the fit for purpose of the weld 3. ACC ( Drooping are ) power source is suitable for @ MMA - TIG b. MIG/MAG - FCAW welding process ¢. SAW ~ MIG/MAG d. MMA - MIG/MAG V8 In Gas Metal Arc Welding (GMAW ) , spray Transfer may be achieved using shielding gases containing ret © More than 85 % argon b. Less than 50 % Argon c. 100 % carbon dioxide I d. Less than 75% argonVy 25. 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 (© Will be higher than the stringer bead because the travel speed will be! lower ‘The same as that for the stringer bead £26. Welding in cold weather conditions is mostly commonly associated with increased risk of : a. Undercut D porosity XK ¢. Slag Inclusion 6 Cracking 47. Hydrogen trapped in the weldment can cause hydrogen eracking ifthe contents of hydrogen are too high. What is the other name commonly used to describe hydrogen cracking? a. Fissure cracks b. Hot cracks ©. Supercritical cracks (@coa cracks7°28. 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 ? (@To increase the hardness b. To decrease the amount of carbon in the steel ~ To increase the ow temperature toughness of the steel 4d. To improve the tensile strength 29. Travel speed is the rate at which the welding gun progress along the joint. As the travel speed increased : a. The penetration is increased ‘The heat input into the joint decreased and the penetration is, lecreased c. The penetration is decreased and the weld bead becomes higher and wider d. The heat input into the joint is increased 30. The recommended drying temperatures and time required producing a condition below 5 ml Hz / 100 grams of weld metal when using basic electrodes would be :~ a. Below 150° C for 1 hour @®. 250°C for 1 hour wy @ Over 350°C for 1 hour « 4, 600°C for hour ~| Candidate, oP CL (ae FE Date FINAL ASSESMENT MULTIPLE —- CHOICE QUESTION CSWIP 3.1 WELDING INSPECTOR COURSE MFY — 003 ALL QUESTIONS TO BE ATTEMPTED EXAMINATION TIME: 30 MINUTES “. Which of the following mechanical properties of a weld made in carbon — manganese steel is most affected, if the heat input per unit length is excessively high: - a. Tensile strength (& Toughness c. Brittleness 4. Elongation A steel is intended for non load carrying service in air at 800° C— 900° ‘C.What single alloying element would you almost certainly find in order that scaling is minimised Nickel b. Chromium © Cooper ~ @ Molybdenum 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 ¢. Considered to be equal to the thickness of the base metal thickness less 3.0mm G@ Equal to the thickness of the base metal“4. ‘The three mai (GMAW) are: modes of transfer encountered in Gas Metal arc Welding a. Spray, globular and drooping b. Spray, high —are and drooping ~ ©. High -arc, globular and short- circuiting * @ Spray, globular and short - circuiting x5. Weld joints designed with J preparati material. Why? are usually used only on very thick a. J preparations are more difficult to fit than other preparations J preparations require least amount of weld filler metal for a given joint thickness ©. J preparation are expensive because they must usually be machined dS preparations affords limited access to the root of the joint c Which of the following situations is most likely to produce the greatest amount of the direct and reflected ultraviolet light? Submerged are welding & Gas Metal Arc Welding aluminium plate © Brazing - Resistance welding two thin sheet steel ‘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 a (ap The melting temperature of the materials must be above its kindling temperature ~8. ew A10. Au. Slow cooling of liquid metal from high temperature promotes the growth of ; a, Small grains b. A combination of large and small grains ©. Medium grains @ Large grains Dimensional discontinuities become dimensional defects when: a. Specified by the welding inspector — b. Specified by the engineer (© Their dimensions have been found to exceed the set specifications or code ~ d. There is no difference since the terms mean the same The CTOD toughness depends on the following four items rostructure Q Thickness,temperature of the specimen, loading rate and 1 b. Loading rateymicrostructure,notch location and temperature c. Bending rai 1s, weld size, hardness and width of specimen {. Noteh location, weld size, thickness of specimen and temperature ‘The shielding gas that is commonly used with Flux cored Arc Welding process is: a. Argon “@ Carbon dioxide Helium 4. HydrogenMia. As. 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 ¢. Wetting and bead appearance are good @ They can be used on Austenitic Stainless Steel without fear ‘of hydrogen embitterment ‘When using the GMAW process for the welding of aluminium, the liner should made of: x (a.) Nylon b. Graphite c Steel d. A liner should not be used Which is the compulsory part of an electrode classified to BS EN as E 46 3B 160 20 a. E463B 160 b. E463 B 16020 © £4638 d. All of the above In Manual Metal Arc Welding which type of flux covering gives the highest hydrogen level to produce deep penetration a. Tron oxide b. Acid and oxidising ¢. Rutile with addition of iron powder Cellulose*16. Crater pipe in welds made by Manual Metal Are cause by: - a, The electrode too damp b. Condensation of parent metal <. Stress acting along the crater “a Poor welder’s technique ‘When approving procedure to BS EN 288 -3 the welder: - (3) 1s automatically approved »_ Is.approved to the same specification ¢. Is approved to a separate specification 4. Is approved for the same range of approval X18. Which statement with regards to Open circuit voltage is not true:- @ OCV is the voltage between the terminals when welding (6) 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 M49. nverters are: - a. Less efficient than conventional machine ma) © Capable of being either CC or CV ¢. Inferior in volt— ampere characteristics 4. Bulky and heavy <\Ao. 4.70% 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 ¢. Forty two minutes out of every one hour continuously d, Seven minutes out of every hour V21. — 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 @ carbon atoms cause the BCC shape to distort resulting in increased hardness b. Iron transform to pig iron © Carbon dissolves in the iron ~ d. Carbon separates out to form isolated islands martensite %22. Hot shortness is term used to indicate 4 Lamellar tearing b. Hydrogen cracking % Solidification cracking d. Hot electrical shock3. portant point of high temperature steels is that: ‘They can withstand creep failure b. They may suffer re-heat cracking problems They may suffer loss of toughness Y@_ Alor the above Ultrasonics would be preferred over radiography due to:- Ability to find most defects b. Lower skill requirement (©) Ability to detect tami ions 4. Both a) and ¢) #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 penetration is poor Argon increase spatter levels oO Poor cap profile or weld contourX26. Which of the following alloying elements can reduce the effect of ‘ temper brittleness” in steel when operated at elevated (emperature. a. Nickel b. Chromium cc. Vanat Gi Molybdenum ~ m x eat 27. In CO; welding, which modes of transfer is the most suitable to be used in the vertical position a. Globular o Axi spray G Dip or short cireniting d. All of the above < 28. Before use, electrodes classified as BS 639 : 1986 E 42 43 R10 or AWS type E 6013 need to be:- a. Dried for 1 hour at 45°C a b. Dried for 2 hour at above 120°C ¢. No drying or what soever Dried for 1 hour at 120°C max.WELDING INSPECTION STEELS - COURSE REF. WIS 5 MULTIPLE-CHOICE QUESTION PAPER (MCQ.001) Answer ail questions. / At. When “hydrogen controi" is specified for a manual m electrode would normally be: etal arc walding (a) Cellulosic ? (o) tron oxide 2 ) Acid ? Basic ? YA2. You would with certainty recognise a hydrogen conta its (2) Colour? (0) Lengin ? (o) Trade Name ? @ AWS/BS639 Code Letter? ~ A3. When manual metal erc welding is being carried out on an open c site, which group of welders are the most likely to require continuous monitaring ? fa) © Pipe welding (©) Plater welders () Plant maintenance welders ?As. Younotice manust metal arc electrodes, sirioped cf wire, for TIG welding. You would object Seceus2 is too expensive 2 < @ tt (0) The wire woule 22 seo sick ? @ The weld m (@) The wi When open si: attention. What ¥ 8 (2) Electrode tyo: (0) Power plant ryp2 @ cecvose sxac ? (d) Day temperature ? s , + AG. The sizal comeosition in 0.6% manganase, to 0.2% ca: ce of fa) Porosity ? Cracking in the weld area ? (c) Undercut for iillet welds ? FH (6) Lack of root fusion defec:s ? Yar magneic. Which ? garam (0) 9.0% Nickel SiYaa. When TIG welding Austanivc stainiess 5° This is to : sipe, Argon gas backing s caile Prevent oxidation ? (b) Prevent uncerbeze {e)_ Prevent gcrasity ? (0) Controt ihe penetration bead shape ? YA9. Pre-heating 2 Carbon sii manuel mete! arc minimise the riss of: Scanered sorosizy 7 f)) Worm noiz soresity 7 © Parent metal cracking ? (d) Lack of penetration 7 vA10. 'n UK practice, BS459 F. 2 fillet weld is ine YAI1. For open site manual metal welding the following equioment is available. Which iG 9 ‘would you choasa for safe working ? :) Single operator transformer ? 2} Multi og: 3H AC/DC comcosi © Dieselv AI. AI3. Ald. AIS. a \f submerged are weic! be most critical of @_ The woot aep (0) The an {c) The root faca wicth ? (6) The gas cut During CO, welding (2) The wire cia ©) The current revs (©) The gas fi (2) The torch to work angie 7 Preneating for arc walcing applies to (a) Assemioty wel © Assembly and (c}_ Joints over 25; ick only 7 (d) — Cruciform weids only ? 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 oO The weid could (0) The weld matat © ‘ard and brittle ? co sok ? There will on snawaie? fd) The weld wil have ugcercut ?A16. A welder quaiification test is to verify : B)_The shi of te welder 2 (0) The quality of the materials ? () The non-destructive test procedures ? (The manufacturing methods ? “A17. A fabricating procedure calls for fillet welds to be “blended in” by grinding. This is to influence : ing ? (a) HAZ. cra © Fatigue life 2 (c) Residual siress ? () Yield strength ? \A18. Bend test specimens have been taken from a 25mm thick carbon steel butt weld. Which would show lack of inter-run fusion @O Side bend ? fo) Root bend 7 Face bend ? (4) Guided bend 7 E veel ee A19. Lamellar tearing has occurred in a steel fabrication. BEFORE welding could it have been found by ae _ (2) X-ray examination ? 2 (0) Oye (c) Ultrasonic inspeczon 7 Would noi have deen faund by any inspection matned ?You are to oversee the arc welding of some machines fittings ana cadmium plated. Would you : wae (2) Permit it to proceed ? (b) Permit it to proceed with fume exiraction ? © Stop the operation ax once ? (d) Advise the welder to drink milk and proceed ?WELDING INSPECTION STEELS ~ COURSE REF. WIS 5 END OF COURSE MULTIPLE CHOICE PAPER (MCQ.002) Seg, Tee GOULD eo, Name : Answer all questions. S499 Part Il communicates by the use of symbols the type of oint preparation to be used. Listed below are four symbols; which of these indicates the depth ion of the weld required on the joint? iapuanaaa u —e— a aa A oaks anubsh Which of the following symbols would indicate that a weld has to be finished flush on the ‘other’ side.of the weld? A ke ——= B pea — © D =- Vo. z timmy Leg em What two functions in arc welding must be in equilibrium to enable a stable arc to be established? une @® Arc Voltage 8 Current A c Wire/Electrode feed rate D Metal burn-off rate «4. In MMA welding, what parameter is used for the control of penetration into the base material? A Voltage B *" Welding Speed a c Iron Powders in the coating 7 © Current 5. __ Inthe welding of a butt joint made from one side, which of the following controls the profile of the root bead? A Root Face 8 Bevel Angle a @ Root Gap x oD None of the above 6. What type of power source characteristic is required for manual welding? A Constant Voltage B Flat Characteristic Ov Drooping Characteristic“ L D Motor Generator 7.” Which one of the following destructive tests would indicate the toughness of weld metal/parent metal - haz. A Macro B Nick Break c Hardness zk res @ Charpy Vee Notch8. 9. 10. i. Degreasing components are essential for quality welding but some agents may om > © Cause Corrosion Problems ~ Give off Phosgene Gas Leave Residues All of the Above Which of the following chemical elements has the greater effect on the A B Oo” rdérabllity of a steel plate? Molybdenum Chromium Titanium Carbon In MAG/CO, welding, which parameters give the greatest control of weld appearance during dip transfer or short circuiting welding? A Wire stick-out length Amperage Wire feed speed ~ Inductance + In MMA welding, the slags produced can be varied to suit the welding position; which type of slag would be required for welding in the HV position? A @v c D Fluid Viscous None of the above Semi fluid12. 13, 14, 15. The weld metal deposit of manual metal arc electrodes achieves its mechanical strength through? A The Core Wire © c Iron powders with the flux coating ” The Flux Coating < 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 jp © Silicon Pitre faridi fy D Calcium Carbonate Welds made with high heat inputs show a reduction in one of the following properties? A Ductility 7 @® 4 Toughness x c Fatigue Strength D Mechanical Strength In the welding of austenitic pipework, the bore is usually purged with Ar to ? A Prevent formation of porosity in the weld. 8 Prevent burn-through in the root run. Ov Prevent oxidation of the root bead D Eliminate the formation of H,.16. 17. 18. 19. In X-ray work, the quality of the radiogrpahic negative is assessed by the 7 A ® .: c D Density of the Film QI Indicator KVA available Stand-off Distance w A steel described as OT)will have improved tensile properties because it has ? A ® v ere oO Had control of chemical composition Been heat-treated Been quality tested Been vacuum melted Which.one of the following type of steels would give rise to the formation of porosity when autogenously welded with an arc process? A v B © D Fully killed steel Semi killed steel Rimming steel Fine grained steel In submerged arc welding, the use of excessively high voltage would result in? A @ D Insufficient flux melting Excessive flux melting Slag removal difficulties Spatter20. The use of cellulosic electrodes is often made when welding the root pass of > pipes in the field. This is because ? 4 A 8 ov D Hydrogen control is needed ~ y ~ Iron powders in the electrode * 7 x Higher arc voltage can be obtained Shorter arc length can be achieved 21. — Inthe 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 O” c D Cracking in the HAZ The formation of chromium carbides x Cracking in the weld metal Distortion 22. Submerged arc fluxes can be supplied in two forms; these are 7 A B @” Sintered and agitated Agitated and fused Crushed and agglomerated Fused and agglomerated 23. Inasteel which has improved creep properties at elevated temperature, which one of the following elements helps in this improvement ? A B ©” D Tungsten Manganese Molybdenum Carbon24. Welding a steel plate of a CE of .45 would require preheating to ? A ©” c D Prevent the formation of sulphides _ Prevent hardening in the HAZ Prevent the formation of carbides ‘To improve mechanical properties in the weld. 25) Which one of the following processes uses the “Keyholiyig’ system of fusion? 26. 27. A B ©- D Friction welding Diffusion bonding Electron beam welding Autogenous TIG welding In friction welding, is the metal at the interface in the ? A B oO’ D Liquid state Solid state Plastic state Elastic state Welding procedures may require welds to be deposited at a controlled rate heat input. High heat inputs would ? A o” c D Have poor profile < Have larger grain size Have high hardness in the HAZ Have low elongation properties *28. ina tensile test, a brittle material would be indicated if the fracture surface ? A @v c D Shows a reduction in size ;~ |S fiat and featureless Breaks in the weld metal Breaks in the parent material * rterhy lig “yon, 29. What destructive test would be required to ascertain the likelihood of cracking in the HAZ of a weld? aoe PEE A B Cc oY Nick break a). Manual metal arc ~ b) Metal inert gas ~ c), Submerged arc welding . Both A&C X9. __ Undercut is principaily caused by: a) Excessive amps b) Excessive volts c) Excessive travel speed YS @® — Allof the above 10. Undercut is normally assessed by: a) its depth b) its length c) its blending (® allof the above 11.\ A welding procedure is useful to : a) Give information to the welder b) Give information to the inspector c) Give "confidence to a product w D Ailof the abovex42. An essential variable may: a) Change the properties of the weld ~ b) Influence the visual acceptability - c) Require re-approval of a weld procedure uv @® Allof the above X13. A magnifying glass may be used during visual inspection but BS 5289 states that its magnification should be: a) up to 5p YA 2-259 5-106 d) none of thé above 14. When visually inspecting a fillet weld, it would normally be “sized” by : a) the leg lengths b) the actual throat thickness ©) the design throat thickness v @ bothaAac 15. A planar defect is: a) Incomplete fusion defects b) Slag inclusion c) Incomplete penetration v @ BothAaC 16.v Penetrant inspection and magnetic particle inspection are mainly used to : Aid visual inspection Because the application standard says so —~ a) b) cl To confirm ‘visual uncertancies* « Lo All of the above. 17. Defects outside of the limits specified in a standard should always be: a) Repaired v@ Reported to “a senior person" €) Assessed along with ather defects - d) All of the aboveo WELDING INSPECTION, STEELS - WIS 5 MULTI-CHOICE QUESTION PAPER (MCQ.004) SB TTD. Name : Answer all questions +. Movement of the arc by magnetic forces in MMA welding is termed: a) Are deviation b) Are misalignment 2. 4 A metallurgical problem most associated with submerged arc welding is : a) Hydrogen cracking in the HAZ @D Solidification cracking in the weld metal c) Hydrogen cracking in the weid metal d) Lamellar tearing in the weld metal %3. Oxy pressure and nozzle £29) would influence what in flame cutting (&) The temperature required for cut initiation b) The ability to cut stainless steels DK The depth of cut obtainable a d) None of the above 4. V The main usage af are 6utting/gouging processes is in: a) The cutting of sirlgle bevel preparations B The removal of deposited welds c) The cutting of single U-type preparations < d) The cutting/gouging of non-ferrous materials only « ~1-5. V Which of the following processes joins metals plastically: @ Friction welding b) Resistance Welding ©) Plasma Welding: . @) All of the above %6. Which electrode classification would be relevant to AWS AS.1-81: YR =6013 7 7 >») E5133" 3) £7018-GX dé) Fleetweld 5 7. v Which of the following coatings is associated with"Stove" welding: a) Rutile AB Ceiiutosic c) Basic d) Oxidising %8. A common gas/mixture used in MIG welding nickel alloys to combine good levels of penetration with good arc stability would be: a) 100% CO, « CB 100% argon » ©) 80% argon 20% CO, & ) 98% argon 2% oxygena 9. J The type of SAW fiux is more resistant to moisture absorbtion: &D Fused b) — Agglomerated ©) Basic d) All of about the same resistance %10. The flame temperature of oxy/acetylene mixture gas is given as: VB 320°C b) —-2300°C c) so00°C d None of the above 7A11. Alarge grain structure in steels is said to produce: a). Low ductility values V@D Low fractiire toughness values « ©) High fracture toughness values ) High tensile strength ~ 12. The likelihood of brittle fracture in steels will increase with: a) Alarge grain formation % Yh Areduction of in-service temperature to sub zero levels, c) Ferritic rather than austenitic steels VY @ Ailthe abovefa aa 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 @ Anyof the above 14.V Hydrogen cracking in the weld metal is likely when welding: 2) Carbon manganese steels b) Stainless steels ®D Micro alloyed steels (HSLA) d) Low carbon steels 415. _ EN standard 288 would refer to which of the following: a) Welder approval testing < b) Welding equipment Vv @ Welding procedure approvai ¢) Consumables for submerged arc welding 16." Porosity is caused by: a) Entrapped slag in the solidifying weld VER Entrapped gas in the solidifying weld “ c) Entrapped metallic inclusions in the solidifying weld ) None of the above17.V 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) Aside bend test BA face bend test d) None of the above 18.\/ Uttrasonic testing is of advantage in detecting which of the following weld imperfections over other NDT methods: a © Lack of side wall fusion b) Surface undercut c) incompletely filled groove ¢) Overlap eae 19. V The process of tempering is often carried out to regain toughness after which of the following processes: a) Annealing b) —_Normalising QQ Hardening dq) Stress relieving 20. The presence of iron sulphide in the weld metal is most likely to produce which of the following upon contraction of the weld: RD Solidification cracking b) Hydrogen cracking ©) Intergranular corrosion d) Stress corrosion crackingoo 4b TLWI certiteaton & Teining ¥[@= ey Sp Welding Inspection, Steels —- WIS 5 Multi — Choice End of Course Assessment Question Paper (MSR-AWI-1) pte LRT Answer all questions Name: What is the ratio between the leg length and the design throat thickness on a mitre fillet weld with equal leg lengths : ao 4:4 ) beeeeose © 1414:1. d. It depends on the fillet welds dimensions and fit up requirements, Jf 2. Whatis the leg length of a fillet weld? a. The distance from the toe to face. Z b, The distance from the root to fre centre. (© The distance from the root to the toe. d. The distance from toe to toe. M3, Whyis the are shielded, when using an arc welding process? a a. Toeliminate hydrogen from the arc. ~ b. To retard the cooling rale of the solidifying metal © . Toexcluded the atmosphere from the arc region.” 4. The arcis not always shielded when using an arc welding process. Which of the following ig @pplicabld for anone planar defects? — dag pewsily a. They are always repaired. - b. Their existence will result in the removal of the entire weld. @© They are not usually as significant as planar defects. 4. They can only be detected using radiography. WIS 5 End of course assessment Qu paper MSR-AWI-1 issue 1 Date: 8/1/02 1of8WI certification & Training 5. Lamellar tearing is: a A product defect caused during the manufacturing of certain steels @ _ Acrack type, which occurs in the parent material due to welding strains acting in the short transverse direction of the parent material, c. 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, wa 6. ) © | Weld metal, HAZ and the parent material b. Weld metal only. The weld zone associated with a welded joint is: the immediate vicinity. c. The weld metal plus parent material, d. HAZ and parent material. ies in steel may 7. Which of the elements if present in significant quant lead to cold shortness” oe a Sulphur. VB Phosphorous. ©. Silicon. 4. Copper. “, : 5 8. Ablack triangular flag used in conjunction with a weld symbol as to EN 22553 means: a. A specific welding process is required. b. ‘The weld is to be made under constant supervision of a qualified welding inspector. © Welding to be carried out on site (field weld). d. The weld must be subjected to NDT. WIS 5 End of course assessment Qu paper MSR-AWE-I issue 1 Date: 8/1/02 20f8TWI certitication & Training oe Austenitic stainless steel can be readily identified by: @® Lack of magnetic attraction. + b. Its extreme hardness. c. Very shinny appearance. g. None of the above. ‘0. Which of the following is likely to be considered an essential variable on a welding procedure a Achange from an electrode classified to AWS E6011 to an electrode £6012. b. Achange in preheat temperature from 500C to 1500C. A change in welding position from PA to PF. %) All of the above (R11. Which of the following is applicable if the heat input is to high during the deposition of a weld made using the MMA wélding process? “@ Low toughness. ~ b. High susceptibility to hydrogen entrapment. v) High hardness, ¢. High susceptibility to lack of fusion. 42. Which of the following will influence the amount of distortion on a component during and after welding? a. -Heatinput. + b. Lack of restraint,» ©. Material properties. Both a and b. oy Allof the above. WIS 5 End of course assessment Qu paper MSR-AWI-I issue | Date: 8/1/02 30f8TWI certification & Training x, 13. When welding with the MIG welding process using pure argon as the shielding ee gas on carbon steel, which of the following prablems are likely to occur? a, b. “© Copper inclusions and excessive cap heights. ,~ Excessive root penetration and porosity. Slag inclusions and crater pipe. < Lack of fusion and poor cap profiles. %14, tis a requirement to excavate a crack in a welded component; the defect is at least 25 mm in depth, which of the following would you expect to be done to remove the defect? a. e c. vv e. Arc air, ground finish and checked with crack detection Thermal gouging, ground finish and check with MPI. + Oxy-gas cutting, ground finish and checked with crack detection. Both a and b. All of the above. 15. The heat affected zone associated with a fusion weld: a. b c. @yY ‘ Usually has the highest tensile strength. Always exists in a fusion-welded joint. Is usually the area of a welded joint that is the most susceptible to HICC? All of the above, ‘16. — Which of the following welding processes would be the most suited for the welding of carbon steel in excess of 100 mm thickness a. © ° d. Tungsten inert gas Electro-stag Manual metal arc. ’ Plasma arc. WIS 5 End of course assessment Qu paper MSR-AWI-1 issue 1 Date: 8/1/02 40f8TWI certitication & Training M7. av A welding process where the welding plant controls the travel speed and arc gap, but under a constant supervision using a shielding gas mixture of 80% afgon — 20% carbon dioxide is termed as: a & ©. © Amanual MAG process. Assemi automatic MAG process. A mechanised MIG process. « Amechanised MAG process. ‘The purpose of normalising stee!: To modify the grain structure by making it more uniform in order to improve mechanical properties. To soften a material for extensive machining, To reduce fracture toughness. To reduce ductility. Which of the following destructive tests would show the results in joules? a. © c. d. Tensile test Charpy test. « Bend test. Hardness test. Generally the most suitable method of detecting lack of sidewall fusion on a single-V butt weld (30° to 35° bevel angles) would be: @ b. ©. d. e. Ultrasonic testing. Radiographic testing Magnetic particle testing Both a and b. All of the above WIS $ End of course assessment Qu paper MSR-AWI-I issue | Date: 8/1/02 50f8TWI certintestion & Training 21. Ultrasonic testing is preferable to radiographic testing due to: a. Ability to find all defects. b. Lower amount of operator skill required © Ability to detect taminations. d. None of the above 24, Which of the following is never a reason for applying post weld heat treatment. a. Hydrogen release. ~ b, "Stress relieving.» c. Grain refinement. Reducing carbon contents. 22. Lamellar tearing has occurred in a steel fabrication BEFORE welding could, which of the following test methods could have detected it? a. Radiographic testing. © Ultrasonic testing. c. Magnetic particle testing. It could not be found by any testing method. A Incomplete root penetration is most likely due to: a. Welding speed too slow. Welding current too high. « b © Root gap too small. « d. Electrode diameter too small, WIS 5 End of course assessment Qu paper MSR-AWI-1 issue 1 Date: 8/1/02 6of8TWI certification & Training 24. You are to oversee the arc welding of some machined fittings and find that they are cadmium plated. What would you do in this sityation? a. Permit the welding to proceed. b. Permit the welding to proceed with fume extraction. © _ Stop the operation at once. d. Advise the welders to drink milk then proceed. 28. Ona single-V butt weld, the distance through the centre of the weld from root to face is called: a. Reinforcement. b. Penetration. VY © Throat thickness. d. None of the above. %2§. Which of the following flame types would you expect to be used for the cutting of mild steel? a. Carburising flame b.. Oxidising flame. Reducing flame. Oo Neutral flame. » 28 The need for pre-heat for steel will increase if: The material thickness reduces. ® Faster welding speeds ~~ c. The use of a larger welding electrode 4, Albof the above. WIS 5 End of course assessment Qu paper MSR-AWI-I issue 1 Date: 8/1/02 70f8LWI certiteation & Training om Welding Inspection, Steels — Wis 5 Multi - Choice Question Paper (MSR-WI-1) Name: 23 Answerallquestions == 2 “Zp = 262 71, Which of the following butt-weld preparations is Usually the most susceptible to lack of sidewall fusion during the manual metal arcprocess? 7 A double-U butt b. A single-v’butt. c. A double-V butt. d. tis not normally a defect associated with the MMA. welding process. “2, Whatis the leg length of a fillet weld? a. The distance from the toe to face. b. The distance from the root to face centre. © The distance from the root to the toe. d. The distance from toe to toe. ¥ 3. What isthe throat thickness of a filet weld (equal leg lengths)? a. The distance from the toe to the face. ©: The distance from the root to the face centre. ©. The distance from the root to the toe. ¢. The distance from toe to toe, “4. Lapjoints contain: © Fillet welds. - b. Comer joints c. — Buttwelds. 4. Single-bevel butts, WIS 5 Qu paper MSR-WI-I issue 1 Date: 8/1/02 Fo.LWI certitication & Training “6. Adduty not normally undertaken by a welding inspector isto: @. Check the condition of the parent material. b. Check the condition of the consumables. © — Measure residual stress. d. Check calibration certificates. “6. Under most conditions, which of the following welding positions will deposit the most weld metal. fs a. Vertical down. ) b. Overhead.” © Horizontal-vertcal @ Fiat (down nana) What meanKby the term crater pipe: @. Another term for concave root b. Another term given for a burn through. ©. Atype of gas pore, found in the weld crater. @ — Asshrinkage defect, found in the weld crater. af 8. What is meant by the term weld junction? @, The area containing the HAZ and the weld metal. « b. The weld metal and parent metal. « — OQ Th boundary between ti fusion zone and the HAZ. 4. “The partof the weld, which has undergone mélatlurgical changes due to the heat from welding. « The strength of a fillet weld is primary controlled by: } a. Leg length. ! (D Throat thickness. Weld thickness. d. Allof the above. WIS 5 Qu paper MSR-WI-1 issue | Date: 8/1/02 20f7TWI certineation & Training Mo. Acrater crack may also be termed: a Cold crack. b. Tearing. c Fatigue crack © © star crack 11. Which of the following welding processesitechnique is likely to be used for the repair welding of localised porosity in a butt weld? . a. MMA, PG position. b. Mechanised MAG. © Submerged arc. « dg, All of the above. © None of the above. 12, Which of the following welds would be considered in a situation where two Plates are to be joined that overiap (assume no external assess), a Afillet weld. _ ’. — Asingle-bevel butt weld. wk oO — Aplug weld. d. Asingle-U butt weld. 13, _ In the MMA welding process, which of the followin by a welder with a poor technique? Tost likey to be caused Deep weld craters/crater cracks. b. Copper inclusions ©. Hydrogen cracks ¢. Allof the above. WIS 5 Qu paper MSR-Wi-1 issue I Date: 8/1/02 3o0f7TW certification & Training Sf 14. Root concavity is caused by: a. Excessive back purge pressure and entrapped gas. ~ b. Excessive back purge pressure and very high heat inputs. - ¢. Excessive root grinding and a slow travel speed, » “® excessive root grinding and excessive back purge pressure. “45. When inspecting a erical component, the toes of a weld must be: i) @. Always ground flush, #. Must always overiap at least 1.5 mm onto the parent material ©: Must always be inspected using a crack detection method (MPI, DPI), V@ __ None of the above can be selected ~ specification requirements unknown. a x ; 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. YO Seek advice trom higher authority. ~~ ©. Carry out no visual inspection, d. Re-wite the requirements of the specification, = “47. Under mostGrcarielances which of the following do you consider to be duties of a welding inspector? a. The supervision of welders. b. Procedure writing. © aualitying weiders d. Allof the above. WIS 5 Qu paper MSR-WI-I issue 1 Date: 8/1/02 40f718. Which of the following is most likely to cause a burn through a. Root gap too small b. Travel speed too fast. © __ Root face too small d. _Allof the above. Mo. inanare welding process, which of the following is the correct term used for the amount of weld metal deposited per minute? a. Filling rate. * & Deposition rate. ©. Weld deposition. d. Weld duty cycle, « %0. What is the term given for the area of a welded joint just outside the weld metal that has undergone microstructural changes? (&% —Heatatfected zone. b. The weld zone. Fusion zone. c. % d. — Allof the above terms may be used. “21. When carrying out visual inspection, which defect (s) is likely to be’mnissed? a. Linear misalignment. S27 b. Cap undercut. c. Porosity. v Qe Lack of fusion (inter run). *22. Cold lapping is another tetm for: “GY Lack offusion at the toe of a weld, » ». Lack of fusion between weld metal and weld metal. ©.* Undercut at the toe of a weld. d. Both a and b. WIS 5 Qu paper MSR-WI-I issue ! Date: 8/1/02 Sof?et "WI certification & Training | ad “23. Incomplete root penetration is most likely due to: a. Welding speed too slow. b. Welding current too high. ©) Root gap too small. d. —_ Electtode diameter too small. 4 24. Crater cracks are caused mainly by: a. Excessively fast welding speeds b. Improper electrode angle © Hot shrinkage. ~ d. Improper joint design. to face is called: Reinforcement, ad a b. Penetration. © _ Throat thickness. d. None of the above. “28. The throat thickness of a % inch fillet weld is? 2. 27.5mm b. 24mm, i © 135mm. : dg. 12.5mm. v 27. The need for pre-heat for steel will increase if: 2, The material thickness reduces. i F: : i & ‘aster welding speeds ¢. The use ofa larger welding electrode 4. Allof the above. WIS 5 Qu paper MSR-WI-I issue t Date: 8/1/02 25. Ona single-V butt weld, the distance through the centre of the weld from root 6of7WI certieation & Training 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. Asymmetreg! double-V butt c Sing © Singlds 29. Awelding inspectors main attributes include: Knowledge. Honesty aid integrity. Good communicator. a b. c. @ Alll of the above. ¥ 30. A code of practice for visual inspection should cover: © Before, during and after welding, b. Before welding activities only. ©. After welding activities only. da None of the above, WIS 5 Qu paper MSR-W'-L issue I Date: 8/1/02 T0f7TWI certineation & Trai 7 ia FW. n 66,2 Welding Inspection, Steels - WIS 5 Multi — Choice Question Paper (MSR-WI-2) Name: Answer all questions 1. Defects outside the permissible limits of the applicable specification should be: a. The decision is up to the welding inspector. © Repaired. ¢. Always double checked using NDT. Vv d, — Allof the above 2. Elecirodes used in manual metal arc welding can be grouped into three main types, these are a. Oxidising, basic and rutile. b. Cellulose, basic and acidic. ¢. Granular, rutile and basic. ae Rutle, basic and cellulose. ‘Movement of the arc by magnetic forces in an arc welding process is termed: Arc deviation, Arc misalignment, EG b © arcbiow. d. Stray arc. “ A crack type most associated with the submerged are welding process is te a. Hydrogen cracking in the HAZ. @ _ Solidification cracking - c. Lamellar tearing d. > Fatigue cracking. 1S 5 Qu paper MSK.WI-2 issue 1 Date: 8/102 Farswy Certification & Trai 5. Which of the following processes joins metals plastically. @v Friction welding. pao Resistance welding. Are welding. Plasma welding. All of the above. 6. What type of power source characteristic is required for a manual process? a. b, oO 6. Constant voltage. Fiat characteristic. Drooping characteristic. None of the above. 7. Which of the following electrodes and current types may be used for the TIG. welding of nicke! and its.alloys?—_ a Cerium electrode, DC -ve. -_) >, Zirconiuriv eTeetroas, AC. = el c. Thorium electrode, DC +ve. d All of the above may be used 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. Entrapped hydrogen, an increase in hardness and lack of fi Entrapped hydrogen, a reduction in carbon content and lack of fusion WIS 54Qu paper MSR-AI-? issue | Date: 811.02 7 2olsTWI certification & Training 10. " 12. WIS 5 Qu paper MSR-WE2 issue 1 Date: 8/1 02 The main reason for using @ back purge when welding 18-8 stainless ste! with the TIG welding process is to: a. Improve positional welding b. _ Prevent the possibilty of porosity. c. Prevent exCessive raot penetration 4 © Prevent the formation of @ dense oxide layer forming in the root. The possible effects of having a travel speed too fast. Low toughness, slag inclusions and cap undercut High hardness, slag inclusions and @ narrow thin weld bead. « x a ® c d High hardness, excessive deposition and cold laps. « Low toughness, poor fusion and stag inclusions, Poa fc blow sxists when welding with the MMA welding process, this can be Dest reduced or eliminated by a. © ©. 4. A change from AC to DC current. ‘ A change from DC 10 AC current. < A change from DC +ve to DC -ve. o A change from DC -ve to DC +ve When welding a double-V butt weld with the submerged arc welding process the presence of centre line porosity may be due to: Damp flux. saw Contamination on the weld preparations. « Incorrect flux depth + Alll of the above.a TWI certitication & 7 13, The inclusion of an inductance in the welding circuit when using MIG/MAG. welding process is to: @® Control the rate of spatter in the dip transfer mode. v b. __ Itenables the welder to weld in position with the spray transfer mode. ¢. _ Itallows 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. sate oi maging? eee ta’ Af GAdeS able property of aluminium oxide residue, when weiding is that it: a. Decrease weld pool fluidity. é equices ‘more heat to mefjit when compared to alumi cee feusts the welljer to traveltto quickly. « Fhe preselige ofthe oxide makes aluminium impossible to weld. ~ 15. Whicl¥ of the folfowing welding process is most likely to be used for the welding of a small diameter stainless steel pipe, 6mm-wall thickness? © staw , e b. SMAW. c. Submerged are welding, dé. GMAW. #6. When considering the tungsten arc welding process what is the purpose of the ©. down-slope (slope-out) control? a. Ensure good penettion. . b. To prevent are strikifig on the parent material © To help prevent the formation of crater pipe and possible cracking. W d. To help prevent tungsten inclusions during welding. WIS 5 Qu paper MSR-WE-2 issue 1 Date! $71.02 t sorsTW certitcation & Training at 17. When considering thermal cutting'local hardening can be reduced by: 2. Increasing the cutting speed. b. The use of propane as a fuel gas. © Pre heating the material to be cut. d. Alllof the above. 18. _ In.asemi-automatic welding process, which of the following shielding gasigas mixtures would normally give the deepest penetration on steel? a 100% argon @® 100% co, v 2 & —75% argon + 25% CO: d, —_Allof the above would give the same depth in penetration 19. Ina MMA welding process, which of the following statements are false? a. Anare gap, which remains almost constant even if as usual the welder varies the position of the electrode. ’ b. ~ Avollage, which remains almost constant even if as usual the welder, varies the aré Gap. ©. Acurrent, which remains almost constant even if as usual the welder varies the arc gap @ = Aandb v e. _ Allof the above. 20. Which of the following welding process, after the weld is completed normally requires a post weld heat treatment to restore toughness values Tamale Gy @® sw. « Lore ae b. MMA. ¥ v c. MAG. » d, All. completed welds require a post heat treatment, regardies§ of welding process. Ihge per thle AVIS 5 Qu paper MSR-WI-2 issue | Date: 8/102 - sofs mTWI certification & Training 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, bd. OC ve. © ve d. Allof the above. 22. Which of the following statements is false? @_ inthe MMA welding process atectrageG * projiuces a deep narrow weld pool, which is fast freezing. ae v b. DC electrode positive is used for the MAG welding of steel plate. ¢. The word calcium carbonate means limestone d. — Allof the above 23, When considering hydrogen, which of the following welding process would A produce the lowest levels in the completed weld (under controlled conditions) a MMA ‘ ’. SAW. © 16 a a. FCAW. 24, Pre heat prior to the welding of a carbon steel butt weld . 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 © None of the above. v WIS 5 Qu paper MSR-WI-2 issue 1 Date: 871.02 GafsTWA certification & Training ia 25, _ Insteel the element with the greatest effect on hardness is: ‘ @ Chromium. b. Manganese. @ Carvon. x 4. Nickel ee co 26. Fora given voltage and current settings on aiMMA 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. ®© The voltage will decrease. ~ prea d. The voltage will increase. * 27. Which of the following best describes a semi-automatic welding process? 4 The welder is responsible for the maintaining the arc gap and travel speed. ' 4 eo 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 « d. — Allof the above. 28, Whats purpose of a rectifier in a welding sets electrical circuit? a. Tokeep the arc stable when using low current settings © —_Toconvert AC current to OC current. wy ©. To convert DC current to AC current d. — Toinitiate the arc at start up. * Ties abeaiys Den ve WIS 5 Qu paper MSR-WI-2 issue I Date: $/1402 Tors”TLWI cersitcation & Training 29, When calibrating a mechanised MAG welding plant, which of the following applies (WFS = Wire feed speed)? Check — WFS, current, volts and wire diameter. * Check — WFS, joint set-up, gas flow rate and WFS. « a b Check ~ Gas flow rate Sick out lengih, WES and current. « ¢. All of the above. 30. The main usage of the arc air process is: a. The cutting of a weld preparation. The removal of defective welds. For the cutting of non-ferrous materials only. * d For the cutting of ferrous materials only WIS 5 Qu paper MSR-WI-2 issue 1 Date: 8/1/92 80f8vw TWI certitcation & Training “4. 42. WIS 5 Qu paper MSR-WI- Welding Inspection, Steels — WIS 5 Multi — Choice Question Paper (MSR-WI-3) Fe\U Name: " bo Answer all questions The tkelhood 0 of a brittle fracture in steels will increase with: a. The formation of a fine grain structure. @ —_ Areduction in-service temperature to sub-zero conditions. c. Aslow cooling rate. » 2 4 All ofthe above. - Hydrogen cracking in a weld zone is most likely to occur when welding: Carbon manganese stee!s. b. Austenitic stainless steel, © Micro alloyed steel (HSLA), d. Low carbon steel, Preheating for arc welding applies to: oO Assembly and tack welding only. b. doint over ‘over 25 mm thick only ©. Assembly weiding ofl. d. When using the MMA.welding process only. e. Bothaandb, Which of the following destructive tests would indicate the toughness valudof the weld metal/parent metal and HAZ? ~ a. Macro. - : b. Nick break, et Tensile. g Charpy Vee notch. issue | Date: 9/1/02 1of8LWI certitcation & Training /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. O Silicon v d Calcium carbonate, V6. — Welds made with high heat inputs show a(féduction in one of the following properties? oe a. Duetility, ©) Toughness. ¢. Elongation. d. Penetration. V7. Which of the following steel types would give 186-to the formation of porosity when autogenously welded with an are welding process : a. Fully killed steel. b. Semi killed steel any © Rimming steel. - “>. Balanced steel Tp, Which ofthe fotowing elements, which may be added to steel, hes the greatest affect on creep strength Tungsten. Manganese. Carbon. a. b. e. Q Molybdenum. WIS 5 Qu paper MSR-WL-3 issue 1 Date: 9/1/02 2088TWI certitication & Training 9. The HAZ associated with a fusion weld Xa. Cannot be avoided. b. Usually has the highest tensile strength. * © Cusually martensitic, ©” Bothaands ©. Allof the above. A What four criteria are necessary to produce hydrogen induced cold cracking? 752: Hydrogen, moisture, martensitic grain structure and heat, ? . 5 b. Hydrogen, poor weld profiles, temperatures above 200°C and a slow cooling rate. © Hydrogen, a grain structure susceptible to cracking, siress and a 1 temperature below 200°C. i d. Hydrogen, existing weld defects, stress and a grain structure susceptible to cracking. X14. A carbon equivalent (CE) of 0.5%: t 7 @L~ ts high for carbon manganese steal and may require a preheat over 100°C x 6. Is generally significant for carbon for manganese steels and is certainly not to be taker fo consideration for preheat temperatures. ¢. Is high for carbon manganese steels and may require a preheat temperature over 300°C as to avoid cracking ¢. Is cafculated from the heat input formula. x Viz. ina martensitic grain structure what would you expect to increase? Duetility, « a A) Hardness, z c 4. Toughness. All of thé above. WIS 5 Qu paper MSR-WI-3 issue 1 Date: 9/1/02 30f8.TWI certitication & Training b. “Bend test. < ©. Charpy V notch test, 4. Allofthe above, x WIS 5 Qu paper MSR-WI3 issue 1 Date: 9/1/02 Tof8TWI certincation & Training J 29, which of the following are reasons for applying preheat? a. The removal of residual stress. 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. 26. From the following electrode coding E50 4 B 160 20 H5, the compulsory part is: a.- £5038 16020 HS. b. _B 160 20H5. @ 55048. a. None of the above.’ WIS 5 Qu paper MSR-W1.4 issue 1 Date: 9/1/02 To0f8“br % %9 4 30. TW certification & Training Which of the following is applicable to electrode efficiency? a. d. © ‘The mass of metal deposited as a percentage of the mass of core wire melted. iron powder electrodes have efficiencies above 100%. Electrodes of high efficiencies tend to produce welds of a smooth flat profile. Both a and b, All of the above. A Fatigue cracks fracture surface is: a © a. Rough randomly torn. Smooth. Step like appearance. Bright crystalline £6014 electrode would most probably used for welding: © b. c d Low pressure pipework. High-pressure pipework. Vertical down welding on storage tanks 'n a situation where low hydrogen welds are specified. i Which element in steel if present iff signi icant amodnts may lead to hot shortness? _— ‘ee a b. c. Phosphorus. Manganese. Silicon. @ (Sulphur. BED 7 WIS 5 Qu paper MSR-WI-+4 issue | Date: 9/1/02 Bof8Dies © pesppertbotledae Of 4 Willa spartan, The cuits & response Lilibres ofa cullilry wigpubor os A entore thee grabily of worl, ni shot coupler nite. Wh, Smet Arawtigs, The atupets Hall a geen a ra Shp of wipe: O). Segptron before wliing a“ Fugue eurting Wildy : ©) Luparrra Of fr walling wo tupettion aahinlas ere cwildog ~ te fomniliarite. webb. gpliestle todas, sondrrets euagt of Gt Sheps ancl alia crenrngs of (ath ruriion, =70 chsh Ha welllieg deeawnnyts suet as Ces, Pare , wcliter ter bleed babe ttify, ee lltig tosis Acrhifrute. 77 cba. reser of Leopectron Tethy Pio (£70) Heat bare telapl. 10 willng atthe. WD Pthek & cif fh lenn hlry. of Conse wable, yu 7 Te Chacha aepuncst of willy pre sams colt Joy Pte toadihon cabibeaifroce tur bree. i : ve hath Ha wathanel tort prune. BE. SC Pe dpa reer ierthatic f. eb ey lle prpection cf 7 Ae Riek He wecling edge propasitin. ( tubdy fot egy) MW [= A clack Ha correer pre - welling of ttitbertin toulnl Cf Y, Cy tables the. 7 fla vorrea pre lant ~> doce - fp lel Cc sock Of 4 wikths |Laspothon. oetrur heb. tenrg nlly . le wills Dapertor bare fo sek / monilor © emily. afl of tly Pedal wif. ayrik ups Partals below » wh hake pre beat alee. fhe eopuature bets ras bared - fe hath ole mens & wow Tote gram bepew arn. Heap bay ra tongg ~ bh heh «¢ tra fy the we elaleg [mdr tovfrat Suet. wy, Fs, lA. & brand pudd tll ee lle mele EE LI Con hry C. Che tae wp ‘ ey hile tte Scthet welts J Fok then — ay bp me Bvmesio real Ha thy seul. GEO teaure Poa fla. why fe foo ay - moni fla dey how CMW tH dae rar, y dag fe Ihe Cartit oat wd. [allo Gp, ~ shah. allo back gate wy Ha poly spears fl. Pol7 fin neduce, rege ty = te hug rab, holy hue, tooling pape we if My ~ he veajup Ha. orbuah © drarparel flr puler. ~ wis He Mydofed. ant tate fla 4 de bed bad. try pect ub Comal ible Hea [i teers. ~ Tatesnfy, Hk repenr Lif 9) 2 Ml — oy bh le Cours deta. 7 (). Gb Ha repay fo ede Ore barca Hea. He ww lley “tat genkifes foe Hpating- Ce) Aeteera Heat Ha ce exrutriin tarrach atah- as fer ripped pride C) Lerune float Hu. war prtbung cr will be applied. OL Iebeng He rywny., ancl pelihe mie. 0 OC dpajgpester fanlers , han’ Concho fla wapuet ron. rath, ws pastor debe lave pur poral abrteuhes ? [rauly > ta gmy > hewn» At able > food eo tonne > Plage est ft boll Le Wha rtotn wir Heal? wile te whentteke 7 Copel > prac be >. conplutl sft. yee wads.\ oO wu K: Moet Arbus an) Dudeze — and Responstbefth'es Ff 2 balding Frape ctor : Whe duties and Responsibilities Of « wekirng. apectn is tanave U2 yally of sk uk Shel Comptierce wil Crees, Sterdards and dravetnge . Be duders Aha be chycfied Wo Unto broader colegorts C9 Thapeckin befae welding U2 drapeclin ding eating C2 uepectin fle, nalding A Iapectsn ach'kes breld'ng ~ e Ficable ara — e fimialinrige ents T'Cdee , Standinds, Spaesprskds “> deat pditerrs end oreninges 1 Ingest regio. ~ b check ti welding documents Ithe NPE, paR and helden pot prearken dee view q powtim limb, Sopiny peeled ake ~ te check ad ponthr le welling —pararnders outterod A Ue Walding Procedure Lhe , juit pruparetion Pup, dimensional Check, distortion Control elyiques ak . - be nae le adequacies % eld tug Pq uspmenl welder fois fr ax Lb bredion and Condition. ~ Madertads fo cheek Ue Mel? CoApeades tad Belek Carbificetes fr Uke material fo be telded Aral Ue Cortursbler Boar et reer© Hes mapas xy aay aad film op rile O@— follmo'ng Comtedenhing Cap be repane Stat be Confirmed tet he appkerble noT Fechsiquas 4 CH rept 4h hoger aul fis aboule ie G&G Bxtot aed cevanaly 4 tie par | ce gee depats PRoced ne appr fae Compt be repare welding wo pa be do cvinsstatin Codrol bralding — Grapectr Shall tmasrbar dgoumeab vw th fallrseng tony. he Leg ble - 2 trcente 3. oth Bay DE Hehe repudem sak | ‘ Procedine ang @ fo Ge ve Kard | Gye chen Revi tees. Z Aide re tor ay my : | G ben? bat a Bx — andurestimeted ing ts } | daape cor Stall Corey xf all Uke Acfietice eile. fost, Negi ly 4 anledgeakte i teak | Gnd Cmunies | el we Aad phacally dil oomph wetsISO 5817 Weld thickness 3.2.1. fillet weld thickness, c; nominal throat thiek- ness: Height of the largest Irosceles triangle that "can be inscribed in the weld section (see ISO 2553) NOTE 1 in countries in which the leg length. 2, is used as the dimension of a fillet weld, the limits for impertections may be reformulated so that they refer to te feg length. 2.2.2 butt weld thickness, «: Minimum distance from the surface of the part to the bottom of the pen- etration, which cannot be greater than the thickness of the thinner of the parts (see ISO 2553). 3.3 short Imperfections: One or more imperfections of total length not greater than 25mm in any 100 mm tengin of the weld or a maximum of 25 % of the weld length for a weld shorter than 100 mmn. 3.4 long imperfection: One or more imperfections of total length greater than 25 mm in any 100 mm ‘Vength of the weld or 8 minimum of 25 % of the weld length for a weld shorter than 100 mm. 3.8 projected area: Area given by length of weld examined multiplied by the maximum width of weld, 3.8 surface crack area: Area to be considered afer fracture. Welding Technology © 1994 4 Symbols The following symbols are used in tzalet @ nominal fillet weld throat thickness (fillet thick: ness) 6 width of weld reinforcement diameter of pore A size (height oF width) of imperfection iength of imperfection Romina! butt weid thickness or, in the case of partial penetration, the prescribed depin of pen- etration 1 wall or plate thickness = leg length of fillet welds (in case of isosceles right angle triangular section 2=¢/2} 5 Evaluation of welds Umits for imperfections are given in table t A walded joint should normatly be evaluated sen~ arately for oach Individual type of impertection (Nos. f to 25) Different types of imperiection cccuring at any cross-section of the joint may need special con- sideration (see No. 28),ty0>p me ne me yoopndiy rou0 Sapte Jo gress SU, WoL eq pinout evve rtosed peynuies nap ior , woe wey ws ero evo oso fo>p tye>p is0>P vonsensdiy tu, 30 eae yours eonpne se papsfond me ne nr e jedi vr | wens | 2 04 26 ‘;2e0 wie9 “(sue 1 > 14) panned out fyou9 oahu were eae oot sero | a 2 2 ° Sup sayy syas9po) emule peeeetaaet °) 7 EE Be a” - otse ost iu 19901 Aten Jo suoieejsedwy 30) mT suopaepeduly 40} sw — 1 oqelHL es Peo *PIM Hy — WM ae sa nomapeatteey | RE : i 5 b 40} suo}}2eys0dw| 40pentausd yore voasioued eunuon orenouod jemay en} vonenoued jeaay een PREZ venti AOS ‘uojioeyedunt 8107 open oued jeraoy. onensued jeunvony ——~ zor ® sroapns or 8 suwey souesees on wetuins a o2s9 osiso of tu qsvosuu say 208 a 2105 uu 50> y ww ory ww std 4 Hos poiepen | a1 } wu enews suse ge wy ew ‘evorwusory [eroruusosy | ecoruui>y | ou vermea ded very o . 7 a soumsejar 4 ovmepor sprwey suai on sven sepiedw soy 10/9penises jon lam jouRwon, prem jomay — wus ¢ eas iw yew wu g eur Kypxanues avorwwi>y | esvorwuy>y | esrormms ry £08 wer a 2 a jusouys overa) rumwe: snuaseyes wsdujns nerepon pune meee sane Anhcaus Z eu 7 ‘Vs90>4 eosy os ouitdes eee cee Sere eee Sores ree eee eee 30018 pati tis | Aomsucout | or exw a yee wor g eu o>¥ isV0>4 “isc0>¥ ost toren watpmistuot pve eoiea + y aurea wor seen | a vonnnane Daniansd eran 12001 100460220 es veo | a ge 6p 290 = sewives 797 E REZ une ¢ xew wu » eu wu ¢ xew - voyeurs ‘aeoruur>y | goorumray | geituwr>y 15 spse9e | o: yruey onswoneoHidde Uo spusdep soueideooy ea apomdwcine waa 7 7 by ue @ pene 7 fal Pee FPRYYZ Si Be s2umeyes Linauaast Pree 0259 ost ai avy xewue sag () GEE Ye Ye Ky ety ety aS 4 » = | Ie > a ge VIPs Wels tye y war 0} Kew wu of xew esrorssro | romeo ‘Avessanau oq Aew uojjesepisuao jeioeds 4X suonoepioauy Hos 0 WY 20 ws O1 > eve wed OL > - ee 2 pusuey aoumeyes ce tie ozsvosi | vojiseneduiy H4nb 0) suo} >epsedu} 10) 4> Gab wie eb C10 Mt figey » baby eel gts fercl, Lo tan om Peer ruston onl P erase bool peubration 2:6 A liven tS! 209 ey areed. Lu 5. Sar fae ferrasily Bondy Gi Oda eee eee area (t,00) P. Creel 2 ouly 9. barn Harouge Geet iwi 1 ma ting i, 6,u2 or eae Pa Hentai GMS aos mo atil Om Fea Unded want be Zs, Rene y Chik 4, 4 Foor Shp Stud owe ry fares Pe ber hap ple tee tip 23. foot Boe eaanity ey % vy Gp oon oO Sev her Bria (Zw) M6, Cock, of Ste vale ye Z only, : fee Sryfe ardw) _, mais Plath, oS 200! puchutin—€ only come EE ERG OS foor Y pape, ong i fi og. 2o- Sag va biarsjo, CwPLATE ONLY KE) L = Length of defect D = Depth or height of defect W = Width of defect [applicable to inclusions only} [# DEFECT NAME REMARKS MAXIMUM] ALLOWANCE I | Excess penetration® 2.0mm D maximum | 2 | Undereut 10% tup to maximum 15 | 62 3_| Angular misalignment Accept. Are strike/ stray flash +e ‘Not permitted He [5 | Liner misalignment Maximum D Lee. t<10mm-~ 0.8mm t>10mm—10mm | 6 | Cracks ee Not permitted je ony 7_| Overlap sass Accumulative total for both shall | 25 mm in weld face only © | Lack of side wall fusion ot exceed 30 mm (pain weumaéeds length ( aitivs deat) 9 | Porosity / Gas Pores/ Elongated gas | Maximum dimension oF any area” | 15 mun bony cavities (worm hales) pipes ‘or individual (as applicable) 10 | Lack of root fusion ‘Accumulative total for both 25 mun in root length I1_| Lack of penetration Defects shall not execed 30 mm | 12 | Root Concavity tH MaximumDImm |g. | 13 | Underfill /incomplete filled groove 7 Pee ‘Not Permitted help | Lack of fit preree HH . | 14 | Excess weld metal® | Smooth transition is required. All |2iimDmavimum 2 ‘uns shall be blend smoothly. No lack of interun fusion 15 | Mechanical Damage Dependant on depth and blend | Seek advise cow 16 } Inclusions (slag/silica ete) ‘Accumulative total shall not Individeal maximum | ¢ ¢ a exceed 20 mm ‘L” in weld length | L<12mm/W<3mm | fee ee | (root & face independent) HH | [ae GaP * When linear misalignment is present the following shall be applied. Excess weld metal: Maximum height to be measured from a direct line from “lowest plate”, across weldment. Excess penetration: ‘Maximum height to be measured from “lowest” plate,Training Master TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1032) MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 1_| Lack of sidewall fusion 2_| Lack of sidewall fusion + slag _ 3_| Slag inclusion 4_| Lack of sidewall fusion z Z 5_| Lack of sidewall fusion + slag 13mm <> [&[Linear misalignment* 1.8mm _ BEE 7_| Root overlap 8 _| Plate inclusions/laminations** [9] é 10 11 | EXCESS WELD METAL 3.6mm [Reject 12 | EXCESS PENETRATION (sharp) _| 2.0mm _| Reject COMMENTS * Also shows angular misalignment ** Lamination acceptance depends on specification requirements a Excessive penetration taken from the maximum point due to misalignment SIGNATURE: DATE:TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [L.D: AM1032 CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] DEFECT SIZE ACCEPT/REJECT mcs w]e] aes[en| a [afro ii | EXCESS WELD METAL 12 | EXCESS PENETRATION COMMENTS: ‘SIGNATURE: DATE: PRINT FULL NAME: .TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEEFT (LD: AM1032 CHECK PHOTOGRAPH LD MATCHES THIS REPORT ID ALL DEFECTS TO BE REPORTED THEN SENTENCED TO ISO 5817 L D SIZED IF REQUIRED] VEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] DEFECT ACCEPT/REJECT 11 [EXCESS WELD METAL | 12 | EXCESS PENETRATION COMMENTS: SIGNATURE: PRINT FULL NAME:Training Master TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [L.D: AM1031 MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] Lack of sidewall fusion 7 1 Reject_ [2 _| Plate inclusions/lamination** Refer 3_| Lack of interun fusion/slag z Reject 4 _| Lack of sidewall fusion + slag Reject 5__| Lack of sidewall fusion + slag Reject 6 | Root overlap Reject 7_| Gas pores/slag 3 off : Accept 8 _| Slag inclusion (close to sidewall) Reject 9 [Capoverlap Reject 10 | Linear misalignment* 1.6mm _| Reject 11 | EXCESS WELD METAL 3.5mm _| Reject 12 [EXCESS PENETRATION 3.1mm_[Reject COMMENTS: * Also shows angular misalignment ** Laminations — acceptance depends on specification requirements 7 - SIGNATURE: DATE: PRINT FULL NAME:TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1031] ‘CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTE ED IF REQUIRED] ‘THEN SENTENCED TO ISO $817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL, WELDING PROCESS: [MMA/SMAW] DEFECT ———'|_-SIZE_| ACCEPT/REJECT | t l 11 | EXCESS WELD METAL i | 12 [EXCESS PENETRATION _ I I COMMENTS: ‘SIGNATURE: DATE: PRINT FULL NAME:> TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [LD: AML031] CHECK PHOTOGRAPH 1.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORT {AS ZED IF REQUIRED] THEN SENTENCED TO ISO 3817 LEVEL B |STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERI LOW CARBON STEEL WELDING PROCESS: |MMA/SMAW] __ DEFECT SIZE_|_ACCEPT/REJECT .o] 0 ]aJon en] [ua fro [= Tae 10 I T 11 | EXCESS WELD METAL He T 42 | EXCESS PENETRATION COMMENTS: SIGNATURE: PRINT FULL NAME:Training Master TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [L.D: AM1030 MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] Lack of sidewall fusion + slag _ Linear misalignment* Lack of root penetration Lack of sidewall fusion ~ [Reject Lack of sidewall fusion Spurious indications / inclusions 1 2 3 4 5_| Lack of interun fusion + slag 6 7 8 11 | EXCESS WELD METAL 12 [EXCESS PENETRATION (COMMENTS: * Also shows angular misalignment SIGNATURE: DATE: PRINT FULL NAME:TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1030] CHECK PHOTOGRAPH 1.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPOR AND S{ZED IF REQUIRED] THEN SENTENCED TO ISO $817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X19 MAGNIFICATION MATERIAL: LOW CARBON STEEL {MMASMAW] WELDING PROCES. # DEFECT [Size | ACCEPT/REJECT 1 SEEPS Gisobdl Verne mectasiom® => eeseers 2 emcesrie ac 20h teiwrieet meer — 3 SET Se _netinmewr aaes 4 Of SE ume pusjon ptt. 22 OS Semen oF Moe uote rusian bse = REIS) peveer 6 | sere wluacu oar. Latewnb) pereer’ 1 leenece OF 00l PEWE TER TION; bs 08 | peyeer: 8 uses. of DE wmic kurion~ cael | xeteer 9 | sete mccovion- ugiwiey fewer: 10 | cece oe vires Pesionm pScAle Aeveer: 11 | EXCESS WELD METAL be 32 mes KEIECT 12 [EXCESS PENETRATION __ eer COMMENTS: SIGNATURE: Be DATE: 07 oevoaee 2203, PRINT FULL NAME: Szimocaiem7> |TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1030] CHECK PHOTOGRAPH ID MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SiZED IF REQUIRED] THEN SENTENCED TO ISO 3817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL at [MOMLA'SMAW] DEFECT [SIZE | ACCEPT/REJECT 11 | EXCESS WELD METAL 12 | EXCESS PENETRATION COMMENTS: SIGNATURE: DATE: PRINTEULLNAME: =TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1030 CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD ALL DEFECTS TO PORTED [AND SIZED IF REQUIRED] ‘THEN SENTENCED TO ISO 3317 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X19 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: |MMASMAW] ESE DEFECT {_SizE_| ACCEPT/REJECT Joe [aon Jon] [os fro |= [a 10 11 | EXCESS WELD METAL [12 [EXCESS PENETRATION COMMENTS: SIGNATURE: . “DATE: PRINT FULL NAME:Training Master TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1033) MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW] 1_| Cap overlap + 2 Gas pores Reject 2__| Plate inclusions/laminations* Refer 3_| Lack of sidewall fusion + gas/silica Reject z 4 | Lack of sidewall fusion + gas/silica |. Reject 5_| Lack of sidewall and interun fusion Reject 6 _| Lack of sidewall fusion + Gas Reject 7_| Root overlap Reject 8_| Linear misalignment** 0.4mm _| Accept 9_| Lack of interun fusion + silica Reject 10 | Gas cavity 11 | EXCESS WELD METAL (hap) _| 47mm _|Reject 12 [EXCESS PENETRATION (sharp)_|1.4mm_ | Reject 13 Lack of sidewall fusion 14 Poor weld toe transition 15 Silica inclusion COMMENTS; * Laminations — acceptance depends on specifications requirements ** Also shows angular misalignment SIGNATURE: DATE: PRINT FULL NAME:rhe = 4) ten TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [LD: AM1033] CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MAG/GMAW] 5 v DERECT A esece or sme amer Pasion 7 Steste REVEL 2 een on vor une, Etionr + sie ([e-athal| Aeveer 3 eae neowree Laces over pn[m tts | peveer ae <= |4 [ans oourk lestyswreal geenry S99? |S as, pacer Id-os | peweor 3 <8% 6 las reeme _| ede oss oe [T [step wena ag 3g |B [lors renee He i Gas Hones. Is 10 | srarzen. as 11 [EXCESS WELD METAL n= we) regeey - 2. ao . [12 [EXCESS PENETRATION bear =te] pecepr - 28 gitqeae bsiee iimiasatans SIGNATURE: 7 DATE: 0, coms 2003 PRINT FULL NAME: He (Cgmar ey oe D de 24 sizren Weta tionr. + ehee oF ure Fear, Lethe. aecer- 2) 0 he iia res | emer eee eee eee Reece 7 Teale he we Me. (net OF siobumte Futtoar + SiLita, Wweliiitur, be Syb ies. ReVeCI” Nf» ? imenn tis aiid : ine aorta em ewer Peaibm <8 1g Crm amon een saeee eee EE fee 7)Training Master TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [1.D: AM1034) MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] 1_| Lack of sidewall fusion + 2 gas pores Reject 2_ [Lack of sidewall fusion + slag Reject i 3__| Lack of sidewall fusion + slag Reject 4_| Linear misalignment* 0.4mm _| Accept '5_| Lack of interun/sidewall fusion + slag Reject 6 _| Lack of interun fasion + slag Reject ~ [7 [Lack of sidewall fasion Reject a 8__| Plate inclusions/laminations** Refer 9° [Are strike™** Refer 10 11_ | EXCESS WELD METAL eee [12 [EXCESS PENETRATION COMMENTS: * Also shows angular misalignment ** Acceptance depends upon specification requirements te *** Acceptance depends on specification requirements — recommend blend smooth and inspect SIGNATURE: DATE: PRINT FULL NAME:TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [I.D: AM1034) CHECK PHOTOGRAPH LD MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] ‘THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [MMA/SMAW] r DEFECT: SIZE. 1 1 7 eae 3 3 oe 5 6 7 8 : a ny 1 10 I 11 _| EXCESS WELD METAL a 12 [EXCESS PENETRATION, z nee SIGNATURE: DATE: PRINT FULL NAME:TRAINING SAMPLE ONLY MACRO INSTRUCTION/REPORT SHEET [L.D: AM1034| CHECK PHOTOGRAPH I.D MATCHES THIS REPORT LD ALL DEFECTS TO BE REPORTED [AND SIZED IF REQUIRED] THEN SENTENCED TO ISO 5817 LEVEL B [STRINGENT] NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION MATERIAL: LOW CARBON STEEL WELDING PROCESS: [(MMA/SMAW] SSE DEFECT S SIZE | A€GEBT/REJEGTS'| ul I 2 | 3 = [ee 3 Be eee [S_| 6 ¢ et - 8 9 : 10 Ii [EXCESS WELD METAL 12 [EXCESS PENETRATION i ‘COMMENTS: SIGNATURE: DATE: PRINT FULL NAME: —EXAMPLE/WORK INSTRUCTION FOR MACRO CHECK PHOTOGRAPH IDENT MATCHES FORM SUPPLIED. ALL LINE DRAWING & WRITING MUST BE IN INK. ALL MEASUREMENTS IN mm / PHOTOGRAPH@ X10 MAGNIFICATION RECORD ACTUAL SIZES, THEREFORE DIVIDE BY 10. RECORD DEFECTS “AS YOU SEB THEM” THESE MACROS HAVE BEEN MASTERED FROM THE PHOTOGRAPHS INTERPRETATION DIFFICULTIES HAVE BEEN RECORDED. COMMENT ONLY IF A DEFINITE UNCERTAINTY EXISTS: ie SLAG/GAS IN SOME CASES. ws : DEFECT iE CCEPT/REJECT 1_| LAMINATIONS/INCLUSIONS 10mmarca_| ACCEPT* 2_| LACK OF SIDEWALL FUSION +SLAG 4mm_ REJECT 3__| SLAG INCLUSION REJECT a ) 4 LACK OF SIDEWALL FUSION REJECT 7 5 6 in — oy 7 aa 8 9 Poe 10 ~ a 11 | EXCESS WELD METAL 2X4mm_| REJECT oes 12 | EXCESS PENETRATION NONE [ACCEPT I COMMENTS: * Material defect. Acceptance dependent on application. - Seek advice SIGNATURE: cdate DATE: *F/** 7 ee J PRINT FULL NAME: CANDIDATE |TWI training & Certitication CSWIP Welding Inspection Practical Pipe Pipe Weld Test Piece ID Number = 7” Diameter: 6% vrs | watt Thickness er" | Process: ama Material opesow see. | weid Preparation: V Greve wrk. Inspection Carried out in Accordance With Specification: gy Yoy +9 extihon. LPP Face Side: { a 3 eect ono 7r| xs| me Aims ese eer ure, Teo reer leaps Wetec | rere) cao astt; Ae : DOT jue reir oF FeaF Be wre | seuorm of seer. 9- found mupeneuy. Wececace eam meta es See a, 4 10 POOR Cb arpeAnANee on pea J Ott mT Dia Rite OUND Ric OP IEET. femerpee L900 CF hun] a nvr cet Im Me Heep Hee Ake tomer c D A 10 lier TER. aeanae eal Fi sone nr STRAY EE | pare] pare Pee toe fe bow ere Pos ase osae| © vere: OB as Poon or Pre mee. a D-AR =m &ECSHE ENP KEIO. b= be. OB m2 Creety1e OM HOGH. O95. Diy 27 Poon OF bir Med 4 OR 2 ween eur BA. Date: 37. ser 200% ‘Signature: at SFSU rasa aaaaanaamerenmetesreseessaae’ 1-07 c0 780 07. Fiatee te eenttna carn WIS 5 -NIPPIS ss One 22/1201