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CSWIP 3.0 / 3.1 / 3.2

CSWIP 3.1: Question with Answer and

Explanation – Part 21
Date: April 7, 2018 Author: Thanh ( QC ) Nguyen Le 0 Comments
1) When ‘hydrogen control’ is specified for a manual metal arc welding project the
electrode would normally be:
a. Cellulose
b. Iron oxide
c. Acid
d. Basic ( answer )

MMA have 3 type of electrode covering:

+ cellulose ( hydrogen content is 80-90 ml/100 g of weld metal )

+ rutile ( hydrogen content is 25-30 ml/100 g of weld metal )

+ basic (  have the lowest level of hydrogen (less than 5 ml/100 g of weld metal).
Need Careful control of baking and/or issuing of electrodes is essential to maintain
low hydrogen status and avoid risk of cracking.

2)  You would certainly recognise a hydrogen controlled flux covered electrode
from its:
a. Colour
b. Length
c. Trade name
d. BS639/AWS code letter ( answer) 

+ Example AWS electrode flux types:

Cellulosic: flux-ends in 0 – 1
Examples: E6010, E6011, E7010, E8011

Rutile: flux-ends in 2 – 3 – 4

Examples: E5012, E6012, E6013, E6014

Basic: flux-ends in 5 – 6 – 7 – 8

Examples: E6016, E7017, E8018, E9018

+ BS639:

3)  When manual metal arc welding is being carried out on an open construction
site, which group of welders are most likely to require continuous monitoring?
a. Concrete shuttering welding teams
b. Pipe welding teams ( answer )
c. Plate welders
d. Plant maintenance welders

Notes: Welders who are working in high pressure work environments like pressure
vessels, Boilers, Piping and Pipeline.

4)  You notice manual metal arc electrodes, stripped of flux, are being used as filler
wire for TIG welding. You would object because:
a. It is too expensive
b. The wire would be too thick
c. The metal composition may be wrong ( answer )
d. The wire is too short

Note:  Function of the Electrode Covering:

 – To facilitate arc ignition and give arc stability
– To generate gas for shielding the arc & molten metal from air contamination
– To de-oxidise the weld metal and flux impurities into the slag
– To form a protective slag blanket over the solidifying and cooling weld metal
– To provide alloying elements to give the required weld metal properties
– To aid positional welding (slag design to have suitable freezing temperature to
support the molten weld metal)
– To control hydrogen contents in the weld (basic type)

5) When open site working, serious porosity in metal arc welds is brought to your
attention. What would you investigate?
a. Electrode type
b. Power plant type
c. Electrode storage (answer)
d. Day temperature

Note: Causes porosity:

Excessive moisture in flux or preparation

Contaminated preparation
Low welding current
Arc length too long
Damaged electrode flux
Removal of gas shield

6)  The steel composition in a structural contract is changed from 0.15% carbon
0.6% manganese, to 0.2% carbon 1.2% manganese. This might influence the
incidence of:
a. Porosity
b. Cracking in the weld area ( answer )
c. Undercut for fillet welds
d. Lack of fusion defects

Notes:

The weldability of steel is mainly dependant on carbon & other alloying elements
content.

With above changing: from 0.15%C & 0.6% Mn to 0.2%C & 1.2% Mn: it means change
from Carbon steel to Carbon Manganes steel

Carbon-Manganese Steels:

Manganese up to ~ 1.6%
Carbon steels with improved toughness due to additions of Manganese

Carbon (C): Major alloying element in steels, a strengthening element with major

influence on HAZ hardness. Decreases weldability.  typically < ~ 0.25%
Manganese (Mn): Secondary only to carbon for strength, toughness and ductility,
secondary for de-oxidiser and also reacts with sulphur to form manganese
sulphides.  typically< ~0.8% is residual from steel de-oxidatio,up to ~1.6% (in C-Mn
steels) improves strength & toughness.

The weldability of the material will also be affected  by the amount of alloying
elements present.

7) One of the following alloys is non-magnetic – which?

a. 4.0% chromium molybdenum
b. 12.0% chromium
c. Austenitic stainless steel ( answer )
d. 9.0% nickel steel

In stainless steel group, only Austenitic stainless steel is non-magnetic.

8) When TIG welding austenitic stainless steel pipe, argon gas backing is called
for. This is to:
a. Prevent oxidation ( answer )
b. Prevent underbead cracking
c. Prevent porosity
d. Control the penetration bead shape

Notes: back purging is done to prevent the formation of oxides inside of the pipe,
which are caused by the presence of oxygen.

9)  Pre-heating a carbon steel manual metal arc welding is carried out to minimise
the risk of:
a. Scattered porosity
b. Worm hole porosity
c. Parent metal cracking ( answer )
d. Lack of penetration

Note: are used to increase weldability, by reducing sudden reduction of temperature,

and control expansion and contraction forces during welding.

Advantages of preheat:
 Slows down the cooling rate, which reduces the risk of hardening
Allows absorbed hydrogen a better opportunity of diffusing out, thereby reducing
the risk of cracking
Removes moisture from the material being welded
Improves overall fusion characteristics
Lowers stresses between the weld metal and parent material by ensuring a more
uniform expansion and contraction

10)  In UK practice, BS499 specifies that the drawing dimension quoted for a fillet
weld is the:
a. Leg length ( answer )
b. Throat thickness
c. Weld width
d. Actual throat thickness

The UK has traditionally used BS 499 Part 2. This standard has now been superseded
by BS EN 22553, however in many welding and fabrication organisations there will
be old drawings used that make reference to out of date standards such as BS 499 Pt
2.

https://www.twi-global.com/technical-knowledge/job-knowledge/a-review-of-the-
application-of-weld-symbols-on-drawings-part-1-064/

https://www.twi-global.com/technical-knowledge/job-knowledge/a-review-of-the-
application-of-weld-symbols-on-drawings-part-2-065/

11) For open site manual metal welding the following equipment is available.
Which would you choose for safe site working?
a. Single operator transformer
b. Multi operator transformers
c. AC/DC composite power unit
d. Diesel engine driven motor generator ( answer )

There are four basic types of power source:

AC transformer
DC rectifier
AC/DC transformer-rectifier
DC generator

AC electrodes are frequently operated with the simple, single phase transformer with
current adjusted by means of tappings or sliding core control.

DC rectifiers and AC/DC transformer-rectifiers are controlled electronically, for

example by thyristors. Modern power sources called inverters use transistors to
convert mains AC (50Hz) to a high frequency AC (typically 50 kHz) before
transforming down to a voltage suitable for welding and then rectifying to DC.
Because high frequency transformers can be relatively small, principal advantages of
inverter power sources are undoubtedly their size and weight when the source
must be portable.
12)  If submerged arc welding is used to make butt welds, which would you be
most critical of?
a. The root gap tolerance ( answer )
b. The angle of preparation
c. The root face width
d. The gas cut finish

Root Gap is very importance for accessibility joint.

13) During CO2 welding, the arc length is most likely to be affected by:
a. The wire diameter
b. The current return connections ( answer )
c. The gas flow rate
d. The torch to work angle

The reaction of the magnetic field that surrounds the MIG wire tip and the current
flow in the plate to the current return cable can be sufficient to deflect the arc
plasma and weld bead. Reducing the arc current magnetic field deflection can be
reduced by positioning the current return cable so that welding is always towards
or away from the ground clamp.

http://www.weldreality.com/arcblowarticle.htm
14) Preheating for arc welding applies to:
a. Assembly welding only
b. Assembly and tack welding ( answer )
c. Joints over 25 mm thick only
d. Cruciform welds only
Preheat are used to increase weldability, by reducing sudden reduction of
temperature, and control expansion and contraction forces during welding.

15) Which one of the following statements is correct?

a. Preheating increases hardness
b. Preheating increases cooling
c. Preheating increases dilution ( answer )
d. Preheating increases shrinkage stress

The end!

Document refer:

+ TWI

Published by Thanh ( QC ) Nguyen Le

 -QA/QC in offshore / ship building / welding field -Worked at Triyards -Worked at
Hyundai Vinashin View all posts by Thanh ( QC ) Nguyen Le

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