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Welding Inspection, Steels - WIS 5

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

Name: ................................ '" .................. ..

Answer all questions

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

lack of sidewall fusion during the manual metal arc procel'ls?
G) A double-U butt. \
b. A single-V butt.
c. A double-V butt.
d. It is not nonmally a defect associated with the MMA welding process.

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

a. The distance from the toe to face.
b. The distance from the root to face centre.
(0 The distance from the root to the toe.
d. Its 0.7 of the design throat thickness.
e. Both c and d

3. What is the throat thickness of a fillet weld (equal leg lengths)?

a. The distance from the toe to the face.

@ The distance from the root to the face centre.

c. The distance from the root to the toe. I

d. ;e The distance from toe to toe.

4. Comp,ound welds:
a. .Always contain butt and fillet welds
b. Joints, which have combinations of welds made by different welding
processes.
Combinations between two different weld types
All of the above.

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issue 5 Dare: 17/01/10 \
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T HE WELDING INSTITUTE

5. A duty not normally undertaken by a welding inspector is to:

a. Check the condition of the parent material.
b. Check the condition of the consumables.

~
Measure residual stress.
Check calibration certificates. \
6. Under most conditions, which of the following welding positions will deposit the
most weld metal.
a. PG.
b. PE.
c. PC.
G
PA.

7. What meant by the term crater pipe:

a. Another term for concave root
b. Another term given for a bum through.
c. A type of gas pore, found in the weld crater.

@ A shrinkage defect, found in the weld crater.

8. What is meant by the term weld junction?

a. The area containing the HAZ and the weld metal.
b. The weld metal and parent metal. \
It;) The boundary between the fusion zone. and the HAZ.
-,<;>Y The part of the weld, which'has undergone metallurgical changes due
to the heat from welding.

9. The strength of a fillet weld is primary controlled by:

a. Leg length.

Gc. Design throat thickness.

Actual throat thickness.
I
d. All of the above.

10. Which of the following is applicable for none planar defects?

a. They are always repaired.
b. Their existence will result in the removal of the entire weld.
CP They are not usually as significant as planar defects.
d. They can only be detected using radiography.

WIS 5 Qu paper MSR-WI-I 20f 8

issue 5 Date: 17101/10
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11. Which of the following welding processes/technique is likely to be used for the

o repair welding of localised porosity in a butt weld?

b.
MMA, PG position.
Mechanised MAG.
c. Submerged arc.
d. All of the above.
--vX None of the above.

12. When measuring the welding parameters with the MMA welding process for
the purpose of approving a welding procedure, the Welding Inspector should
measure the voltage:

Gb. As close to the welding arc as possible.

c.
d.
Anywhere along the welding cable.
Always from the voltmeter on the welding plant.
As near to the welding terminals as possible.
l
13. In the MMA welding process, which of the following is most likely to be caused
by a welder with a poor technique?

CV Deep weld craterslcrater cracks.

b.
c.
d.
Copper inclusions
Hydrogen cracks
All of the above.
l
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. l

15. When inspecting a critical component, the toes of a weld must be:
G b.
Always ground flush.
Must always overlap at least 1.5 mm onto the parent material.
c. Must always be inspected using a crack detection method (MPI, DPI).
ClX None of the above can be selected - specification requirements

unknown.

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issue 5 Date: 17/01/10
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16. When carrying out visual inspection, the specification makes no mention of the
requirements for visual inspection, in this situation what should you do?
Carry out normal visual inspection. ,
Seek advice from higher authority.

Carry out no visual inspection.

d. Re-write the requirements of the specification.

17. Under most circumstances, which of the following do you consider to be duties
of a welding inspector?
a. The supervision of welders.
b. Procedure writing. 1
~
Qualifying welders I

All of the above.

18. Which of the following is most likely to cause a burn through

a. Root gap too small.
b. Travel speed too fast.
('5 Root face too small
d. All of the above.

19. In an arc welding process, which of the following is the correct term used for

the amount of weld metal deposited per minute?

a. Filling rate.

c:!
d.
Deposition rate.

Weld deposition.
Weld duty cycle.

20. What is the term given for the area of a welded joint just outside the weld

ometal that has undergone microstructural changes?

b.
Heat affected zone.
The weld zone.
c. Fusion zone.
d. All of the above terms may be used.

WIS 5 Qu paper MSR-WI-l 40f 8

issue 5 Date: 17/0111 0
 TWI
Vfl!ll.----------_____ THE WELDING INSTITUTE
21. When carrying out visual inspection, which defect (5) is likely to be missed?
a. Linear misalignment.
b. Cap undercut.
c. Porosity.

-t(9 Lack of fusion (inter run).

22. Cold lapping is another term for:

(~ .
.~ Lack of fusion at the toe of a weld.
b. Lack of fusion between weld metal and weld metal.
c. Undercut at the toe of a weld.
_A) d. Both a and b.

23. Incomplete root penetration is most likely due to:

a. Welding speed too slow.
b. Welding current too high.

c;> Root gap too small.

Electrode diameter too small.

24. Crater cracks are caused mainly by:

a. Excessively fast welding speeds
b. Improper electrode angle
cy.
d.
Hot shrinkage.
Improper joint design.

25. On a single-V butt weld, the distance through the centre of the weld from root
to face is called:
a. Reinforcement.
b. Penetration.

<£> Throat thickness.

d. None of the above.

26. The throat thickness of a % inch filiet weld is?

a. 27.5 mm fb
b. 24mm.

~
13.5 mm.
12.5 mm.

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issue 5 Date: 17101/10
TWI
rll!ll.-----­__________ THE WELDING INSTITUTE

27. The need for pre-heat for steel will increase if:
15 f'I . tO~1
a.

®c.
d.
The material thickness reduces.

Faster welding speeds

The use of a larger welding electrode
All of the above.
11 t-'\",J 'L THf<.·

'l.,..) l~;):r IVlPu t

!
~ 1 lii""Jyoer Y\ see-I.(: fl.) f; ) (,., ~ I G
28.
for the welding of a 6mm thick plate? 't) e64-' /.. c
Which of the following butt weld preparations is most likely to be considered
4'
-
tVllll
a. Double-V butt. , to
c. Single-U butt.
LP Single-V butt.

29. A welding inspectors main attributes include:

a. Knowledge.
b. Honesty and integrity.
c. Good communicator.

CV All of the above.

30. A code of practice for visual inspection should cover:

fa""':) Before, during and after welding.
V. Before welding activities only.
c.
d.
After welding activities only.
None of the above.
)
31. When manual metal arc welding is being carried out on an open construction
site, which group of welders are the most likely to require continuous
monitoring?
<: '
a. Pipe welders
b. Structural welders
c. Welder fitters

@ Bothe a and b

e. All of the above

WIS 5 Qu paper MSR-WI-I 60f 8

issue 5 Date: 17/01110
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32. When open site working, serious porosity in metal arc welds is brought to your
attention. What would you investigate? ...._ ­
a. Electrode type

G d.
Electrode storage
Day temperature
Power plant type .
e. All of the above.

33. What is the maximum allowable HIILO for 8mm material if the code states the
following. "Linear misalignment is permissible if the maximum dimension does
not exceed 10% of t up to a maximum of 2mm"

~ ~~~m )
c. 8mm
d. None of the above, insufficient information provided

When conducting a visual inspection on a butt weld you notice an excessive

­
34.
"Veed" cap ripple on the cap. This may indicate which of the following
a. Incorrect electrode
X Excessive travel speed·

Incorrect pre-heat applied

@ All of the above.

35. Toe blending is generally carried out:

G To reduce the possibility of fatigue failure I
b. To improve the toughness of the welded joint r
c. To increase the Ultimate Tensile Strength of the welded joint
d. All of the above.

36. When visually inspecting a fillet welded Tee piece, which of the following is
normally measured to determine the fillet welds size.
X Leg length
b. Throat thickness

o
c.

e.
Design throat thickness
Both a and b.
All of the above ..

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issue 5 Date: 17/01110
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37. What is the maximum lack of root fusion permitted.

G) 30mm in any continuous length

b. Lack of root fusion is not permitted.

c. Lack of root fusion is permitted regardless of length.
A None of the above.

38. Defects outside the permissible levels of the applicable specification/standard

requirements should always be:
& b.
Repaired
The action taken depends on the welding inspector. \
c. accepted \
d. Radiography and Ultyrasonic carried out again regardless of the initial
inspection methods carried out.

39. Arc strikes associated with a welded joint may be considered a serious defect.
Because
a. The presence of arc strikes may lead to hardening of the parent
material
b. The presence of arc strikes may lead to cracking
c. The arc strike may cause a reduction in parent material thickness.
d. Both a and b.

LV All of the above.

40 Which of the following defects would usually be considered the most serious.
a. Lack of interun fusion.
b.

CVd.
e.
Slag inclusions.

Lack of fusion, surface breaking

Porosity
All of the above.
I

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issue 5 Date: 17/01/10