Practice Examination and Sample Questions for Visual Inspection Workshop American Welding SocietyIW PRACTICE EXAMINATION, xr to Part B Specification ead each question carefully and select the one best answer. Itis helpful for you to write down the Appendix ‘umber(s) and page(s) where you find the answer. The exam should be completed within a two hour period. |. The designer is specifying the joint designation, B-U2-GF, for the welding of two structural members. What is the maximum acceptable range of root opening dimensions, as detailed, available to the designer for that joint configuration? : © ot 18inch i a 1/16 inch to 3/16 inch LeAp eB © oth QR 6. Oto tit ach 3 ie 4. 0 t0 3/16 inch . none of the above 2, Where should the designation A5.18 be placed on the Appendix I form? sa. space # 5 b. space #6 «. space #7 4. space #1 ©. none of the above b 4, Which of the following would be a matching electrode for GMAW of AS72 Gr 60 steel? a, ER70S-XXX, +b, ER80S-XXX , ER90S with 20 f-lbs minimum impact strength at 0°F 4. ERIOOS-XXX . none of the above “sind 4. For GMAW welding of 3 inch thick A517 Gr 100 steel, what is the required preheat and interpass temperature? $i a. 25°F minimum r by. 225°F maximum + © 25°F minimum to 450° F maximum 4. 225°F minimum to 400° F maximum «none of the above Questions 5 and 6 refer to the Butt Joint weld sampl 5. Is the depth of the undercut on this weld sample acceptable if the weld axis is parallel to the primary stress? a. yes +b. no ¢. no acceptance criteria provided & not enough information provided €. none of the above 6. Is the amount of weld reinforcement on this sample acceptable? yes b. no €. mo acceptance criteria provided 4, not enough information provided ©. none of the above7. Which of the following processes would be acceptable for the prequalified joint B-U2a-GF? a. FCAW b. SMAW ©. GTAW d. SAW e. none of the above The following information applies for questions 8 through 13: A welding procedure is being qualified for the welding of A572 Gr 60 plate for a structural application. The welding process to be used is a FCAW, and the weld configuration is a single-V-grooye weld with a steel backing. The thickness of the test plate is 1-1/2 inches. This procedure qualification coupon is being welded the horizontal position for plate. 8. What is the matching filler metal classification for this base metal? A a. ELIXTX-X fe b. BLOXTX-X c. EOXTX-X d. ESXTX-X e. none of the above 9. What is the required preheat and interpass temperature for this procedure? a, 150°C minimum to 205° C maximum b. 150° F minimum to 400° F maximum ee. 150°F minimum 4. 225° F minimum ©. 300° F minimum 10. For what maximum thickness will this procedure be qualified if the required tests are successfully passed? 2. 3/4 inch b. 3 inches maximum =. unlimited thickness 4. 3/4 to 1-1/2 inches fe. none of the above 11, If the welder who performs this procedure qualification is successfully qualified, in what positions is that individual qualified for production welding? 4+ a. horizontal groove and fillet welds in plate b. flat and horizontal grooves in plate ¢. flat and horizontal grooves in pipe if the pipe is greater than 24 inches diameter with backing or backgouging flat and horizontal fillets in pipe # ©. allof the above 12, What is'the F number of the filler metal required for this qualification test? al b3 66 as fe. none‘ofthe above + Revised June 1. we13, What test specimens are required for this qualification test? a, 2 reduced section tensiles, 2 root bends, 2 face bends +b, 2reduced section tensiles, 4 side bends ©. 2 reduced section tensiles, 2 macroetch specimens, 4 side bends 4d. 2 reduced section teusiles, 2 macroctch specimens, 2 ruot bends, 2 face bends c. none of the above 14, A shielding gas flow rate is 7.5 liters per minute. What is the flow rate in cubie feet per hour? 159 fi 3.54 159 354 12.8 15. During the evaluation of a guided bend test specimen, a 5/16 inch corner crack is observed. There is no evidence of slag inclusions or other fusion type discontinuities. The specimen is: a. acceptable b. rejectable because the crack is greater than! /4 inch long «. rejectable because the crack is greater thant/8 inch long 4. disregarded and a replacement specimen should be removed from the original weld . disregarded and a replacement specimen should be removed from a different weld 16, Where should the designation E6010 be placed on the Appendix I form? a. space # 5 b. space #6 c. space #7 4. no prescribed place for this information ¢. this information is not applicable for procedure qualification Questions 17 and 18 refer to the largest T-Joint sample 17, Based on the actual size of the filet weld on Side A, what is the maximum size this weld will meet per the Par®B Specification? a. 1/4 inch b. 9/16 inch ©, 3/8 inch d. 7/6 inch €. none of the above 18. The discontinuity occurring inthe region ofthe fillet weld from 0 to AL is properly referred to as a. root porosity b. linear porosity . cluster porosity 4. aligned porosity €. wormhole porosity Revised JuneQuestions 19 and 20 refer to the smallest T-Joint sample 19, Is the porosity at location A1 acceptable? a. yes no. T° b cc. cannot be determined . no acceptance criteria given e. none of the above 20. Is the porosity at location A2 acceptable? a. yes b. no cc. cannot be determined 4d. no acceptance criteria given c. none of the above The following information applies for Questions 21 through 2 Awelder successfully qualifies on a groove weld in the 5G position on 8 inch, schedule 80 pipe using the SMAW process. The pipe materials are API SLX, Grades X42 and X52. 21. For what maximum thickness range is this qualification valid? a. 5/16 inch through 3/4 inch . 1/2 inch through 1 inch c. 0.187 inches to unlimited + d. all of the above . none of the above 22. Which electrode classification is an appropriate matching filler metal for this qualification to Part B? a. E7018 b. £7028 ©. E6010 d. both a and b above e. none of the above 23. For what range of pipe diameters is this quali a. 1 inch through 4 inch b. 4 inch and smaller . 4inch and larger 4. tes diameter and below e. all diameters 24. What test specimens were required? a. 2 face bends, 2 root bends b. I face bend, 1 root bend ©, 2 face bends, 2 root bends, 2 reduced section tensile samples 4. 4 side bends, 2 reduced section tensile samples e. 4 side bends Revised June 2006 ee 30,What isthe required preheat and interpass temperature for this joint? none required none if the base metal is above 32° F 50° F minimum | 150° F minimum 50° F minimum and 400° F maximum Vinat F number(s) apply to the proper filler etal for this application? Land 6 . 2and 6 Land 4 . 4only . Loaly ns 27 through 29 refer to the sample tensile specimen A. What is the width of the reduced section? . 0.45 inches . 0.50 inches 12.7 millimeters _ 15.4 millimeters bande above What is the thickness of the reduced section? 0.20 inches 5.1 millimeters 0.25 inches both a and b above | both b and c above Jsing the answers from Questions 27 and 28 above to calculate an area, what is its tensile strength if it exhibited 1 maximum load of 8560 pounds during the tensile test? Tensile Strength = Load ar 168,000 psi 68,480 psi "72,500 psi | 74.500 psi 15,000 psi the specimen from Question 29 was taken from a piece of 2 1/2 inch thick A588 steel, does it meet the cification requirements for tensile strength? yes impossible to determine from the information provided no value for required tensile strength provided none of the above31. Ifa welder completes a weld joint in the 6G position for a welder qualification test by starting the weld at the 7. Is ¢ bottom of the pipe and travels upward towerd the top, where should that information regarding the welding ay direction be placed on the Appendix II form? br a. space #3 er bi. space #7 ar ©. space #12 er space # 16 +e, none of the above 8. Usi sat Questions 32 and 33 refer to the smallest T-Joint sample. i : 32. Is the porosity at locatior! BI on Side B acceptable? ah nye et . no ¢. cannot be determined 4. no acceptance criteria given Quest e. none of the above 33, ‘The porosity appearing at BI, Side B, would best be described as: 9. Spe a. linear or aligned porosity aa b. cluster porosity bin ©. wormhole porosity en 4. elongated porosity an €. grouped porosity eb 34. What is the heat input for a weld made with the GMAW process using 26 volts, 260 amperes, and a travel speed 0. Spe of 6 inches per minute? aa ben Heat Input = Amps x volts x 60 en ‘Travel Speed (ipm) ar a. 64,000 Jinch eb b. 66,000 Finch «. 66,600 Jinch 1. Spe 4. 67,600 Finch aa ©. 68,000 S/inch br Questions 35 through 37 refer to the sample Fillet Weld A. oe e 35. What rejectable discontinuity exists in the fillet weld on Side 1? a. toe erack 2 Sp ». erater erack aa . underfill oe 4. exéessive weld reinforcement oS . overla r ° et 36: Ifthe fillet weld on Side 3 is measured, what is the maximum fillet weld size it will meet per Part B? a. 3/16 inch 3. Ist b. 1/4 inch . © 5/16 inch » 3/8 inch ° . none of the above é Revised June 20067. Isthe undercut on Side 4 acceptable if the weld axis is transverse to the direction of primary stress? yes no no acceptance criteria provided not enough information provided none of the above 18. Using a matching filler metal for 1 inch thick A516 Gr 70, what is the minimum required yield strength ofthis material? B +a 38ksi », 38,000 psi ©. ST ksi 4. both a and b above e. none of the above 39. Specimen A is re a. acceptable ». rejectable because of comer erack(s) ¢. rejectable because of cracks(s) on the convex surface d.rejectable because of porosity on the convex surface : ce. both b and ¢ 40. Specimen B is f a. acceptable b. rejectable because of comer erack(s) c. rejectable because of cracks(s) on the convex surface : dd rejectable because of porosity on the convex surface i both c and d t 41. Specimen Cis t a. acceptable b. ejectable because of comer erack(s) ¢.rejectable because of elongated discontinuities on the convex surface a rejectable because of porosity on the convex surface e.bothb ande 42. Specitnen Dis a. acceptable ». rejectable because of comer crack(s) cc. rejectable because of cracks(s) on the convex surface d.rejectable because of porosity on the convex surface e. both b and © 43, Is the welder who welded this test weldment qualified ifall the bend test samples are required for qualification? a. yes b. no, because Bend A is rejectable c, no, because Bend B is rejectable d. no, because Bend C is rejectable fe, no, because both Bends A and C are rejectableQuestions 44 through 46 refer to the Fillet Weld Sample A. 44, Ifthe shop drawing requires a 5/16 inch fillet weld, is the weld on side 3 acceptable? a. yes What i b. no et ¢. no acceptance criteria provided b. 0.81 4. not enough information provided ©. 08 ©. none of the above on . nor 45. Which ofthe following discontinuities are present on Side 1? a. underfill and excessive reinforcement What ». overlap and elongated surface porosity se ¢. undercut and overlap ». 02 4. undercut, elongated surface porosity and overlap aun ¢. undercut and elongated surface porosity 4. bo 46. Is the weld on Side 3 acceptable? a yes Using b no form ©. no acceptance criteria provided 11,03 4. not enough information provided a. 75 . none of the above b. 7S ita w a b. d Revised June 2006IW Sample Questions Refer to Part B Book of Specifications for acceptance criteria What is the width of the reduced section tensile specimen B? 0.75 inches 0.80 inches 0.85 inches 0.90 inches none of the above ‘What is the thickness of the reduced section tensile specimen B? a. 5.8mm ». 0.23 inches ©. 0.185 inches 4. both a and b above €. none of the above Using the answers from Questions 1 and 2 above to calculate tensile specimen B's cross sectional area, and the formula on Page 5 of these exercises, what is specimen B's tensile strength if it fractured at a maximum load of 11,030 pounds during the tensile test?” 15,495 psi 79,500 psi 84,000 psi 89,000 psi 89,500 psi ‘What isthe area of the reduced section of tensile specimen C? a. 0.12 square inches b. 120 square mm ¢. 0.17 square inches 4. both a and b above ©. none of the above - Using the answer from Question 4 above, and the formula on Page 5 of these Exercises, what is Specimen C's tensile strength if it exhibited a maximum load of 13,080 pounds during the tensile test? a. 107,000 psi . 108,000 psi ©. 108,000 psi 4. 110,000 psi @. 111,000 psi If a welder qualifies on a 3/8 inch thick plate groove joint, what thickness of plate groove joint is that welder mot qualified to weld in production? a. 1/4 inch b. Winch ©. 3/4 inch d. 1 inch c. boih band c aboveews 7. Ifa welding procedure is qualified on 10 inch diameter, schedule 20 pipe, for what range of diameters and wall thicknesses is this procedure considered qualified? 1 a, diameters 4 inches and over, wall thicknesses over 3/16 inch er bb. diameters 10 inches and over, wall thicknesses over 1/4 inch, a cc. diameters 10 inches and over, wall thicknesses over 1/8 inch b » d. diameters 10 inches and over, wall thicknesses from 1/8 inch to 1/4 inch ¢ e. diameters 10 inches and over, wall thicknesses from 1/8 inch to 1/2 inch é 8, Is the porosity in section A3 of the smallest T-Joint weld sample acceptable? a. yes b. no 1 . cannot bé determined ‘ d._ no acceptance eriteria given t . none of the above ‘ 9. What is the actual measured weld size on Side B of the smallest T-Joint sample? 76 inch . 1/4 inch S/6 inch 3/8 inch none of the above 10, What is the actual measured weld size of Side B of the largest T-Joint sample? a. 3/16 inch b. 1/4 inch “ce. SAG inch B d. 3/8 inch fe. none of the above 11. Is the porosity in section B2 of the smallest T-Joint sample acceptable? “a. yes b. no . cannot be determined d. no acceptance criteria given a . none of the above 12, What isthe size of the item being measured with the machinists scale in the sketch below? a, 1 and 23/32 inch b. 1 and 23/64 inch ©. Land 21/64 inch +d. Land 21/32 inch e. Land 5/8 inch Revised June 200f and wall 3, The width of a rectangular tensile specimen is 0.762 inch. Using the conversion chart on Page 5 of these xercises, what is the SI conversion? 22.76 mm 20.69 mm 1935 mm 19.15 mm 18.77 mm 4, The thickness of the specimen in Question 13 is 18.70 mm, Using the conversion chart on Page 5 of these Exercises, what is the U.S. Customary conversion? 0,936 inch 0.778 inch. 0.887 inch 0.966 inch 0.736 inch ppeeP 5. Using the required values from Questions 13-14 above, calculate the area of the tensile specimen in square inches and square millimeters. 0.777 square inches and 501.294 square millimeters, 0.555 square inches and 358.062 square millimeters, 0.738 square inches and 476.131 square millimeters 0.561 square inches and 361.845 square millimeters cannot be calculated paeee 6, Ifa tensile specimen fails ata load of 51,550 pounds, and using the values from Question 15, what isis ultimate tensile strength (using the formula on Page 5)? 91,889 psi 82,800 psi 66,400 psi 37,000 psi cannot be calculated pppoe 7. What isthe size of the weld being measured with the fillet weld gage shown below? 5/16 inch 1/4 inch less than 1/4 inch cannot properly measure weld with the gage shown since the weld is conver, it cannot be measured Gap oe18, size. What can be said about the weld measurement being The fillet weld below is required to be 3/8 inch i ‘made in the sketch below? a. the weld is not acceptable because itis too large b. the weld is acceptable ©. the weld is not acceptable because itis too small . cannot accurately determine weld size because incorrect gage is being used iS il The groove weld shown below is required to have a maximum weld reinforcement of 1/32 inch, From the ‘measurement shown in the sketch, what should be said about the weld? a. the weld is unacceptable because there is not enough reinforcement b. the weld is unacceptable because there is too much reinforcement c. the weld is unacceptable because the requirement only applies to the face reinforcement, and the root reinforcement (or face reinforcement if it is a back weld), is being measured d. the weld area being measured is acceptable regarding the amount of reinforcement this gage should not be used to measure reinforcement Revised Fume 200bein oo Conversion Factors ‘é Convert From: To: Multiply By aches millimeters 25.4 iillimeters inches 3.937 x 107 Censile Strength Formula Strength = Load to fracture area athe pota Answer Key Practice Examination and Sample Questions for Visual Inspection Workshop American Welding SocieiyAnswer Key- VIW Practice Examination 1. d_ (Coot opening dimensions from App III, page 3, top sketch, show R= 0 to 1/8. The designer's as detailed tolerance of +1/16 /-0 must be added to the R range to arrive at correct answer.) 2. a (Appl, page 1; the designation is an example of a Filler Metal Specification.) 3. b (App XIV, Group III, page 19, GMAW process.) 4, ¢ (App XV, Group IV, page 19, over 2-1/2 inch requires 225°F for minimum preheat, plus footnote 3 applies to entire table and requites 450°F maximum for thicknesses greater than 1-172 inch,) 5. a (depth of undercut measures 1/32 inch, which is acceptable per App VII, item (6), page 7. 6. a (ace reinforcement measures 1/8 inch maximum, which is acceptable per App V, butt weld Note, page 5, or App VI, item 2, page 6.) 7. a (App Ill, lower sketch, page 3, GMAW and FCAW are the only processes listed for this, joint) 8. 4 (App XIV, Group II, page 19, FCAW process.) 9. © (App XV, Group C, page 21, 1-1/2 inch thickness for 150°F minimum. Note: Footnote 3 on page 21 does not apply to this material.) 10.¢ (App XIII, section 1, Tests on plate, page 16, 1 inch and over.) lle (App XI, page 14, Plate horizontal position is 2G; table shows qualifying in 2G also qualifies for plate groove and plate fillet welds in F, H positions. Plate 2G qualification also qualifies for pipe groove in F, H per footnote 1, and for pipe fillets in the F and H positions.) 12.¢ (App XIV, Group IIl, page 19 shows filler metal specification A5.29. App X, page 11 shows an F number of 6 for this specification) 13.b_ (App XILL page 16, Tests on plate, ! inch and over.) 14,a (No multiplication conversion factor inside front cover, answer obtained by dividing 7.5 by 0.472 = 15.889.) 15.4 (App VIII, page 8, last sentence.) 16.6 (Appl, page 1, the designation is a Filler Metal Classification.) 17.¢ (The sample weld’s minimum size along its length is actually closest to 5/16 inch. Using App VIL, item (8), page 7, the allowable underrun of 1/16 inch permits this weld to meet the requirements of a 3/8 inch weld. 18,¢ (Cluster porosity is not covered in Part B, but is considered required general knowledge.) 19. (App VI, item (7), page 7; porosity measures greater than 3/8 inch total (3/32 + 3/32 + 332+ 4/32 = 13/32) within 1 linear inch.) 20.a (App VIL, item (7), page 7; porosity measures exactly 3/8 inch (4/32 + 4/32 + 4/32 12/32 or 3/8) within I tinear inch.) 21.¢ (App XI, section 2, Tests on pipe, prae 1.) 22.4 (App XIV, Groups I and IL, and footnote 1, pages 15 and 16; filler metal must be an all position, low hydrogen electrode to meet both base metal requirements.) 23.¢ (App XI, section 2, Tests on pipe, page 11.) 24.¢ (App XI, section 2, Tests on pipe, page 11.) 25.6 (App IV, page 4 for wall thickness of 0.500 inch and App XV, Group TIT, page 19 and footnote 4.) Revie ene 200626.4 (App XIV, Group It, page 15, for Specification number and E7018; App X, page 10 for F number.) 27. (Actual measurements are 0.50 inch and 12.7 mm.) 28.c (Actual measurement is 0.25 inch and 6.3 mm.) 29.0 (Area is 05 x 0.25~0.125 square inches. 8,560/0.125 ~ 68,480 psi) 30. (The calculated value of 68, 480 psi is less than the required minimum value for AS88 of 70, 000 psi) 31. (App Il, page 2, note after Position line.) 32. (App VIL, item (7), page 7, weld porosity diameters total less than 3/8 inch (2/32 +3/32 + 2/32. + 3/32 = 10/32 or 5/16) 33.2 (Lincar porosity is not covered in Part B, but is considered required general knowledge.) 34.4 (260x 26x 60 / 6 = 67,600 Joules/inch) 35. (App VI, item (5), page 6; discontinuity is overlap.) 36.c (The sample weld’s minimum size along its length is actually 1/4 inch. Using App VII, item (8), page 7, the allowable underrun of 1/16 inch permits this weld to meet the requirements of a 5/16 inch weld.) 37.b (App VI, item (5), page 7, undercut is grester than 0.01 inch.) 38.d (App XIV, Group II, page 18, under Minimum Yield Point Strengtti) 39.c Rejectable crack on convex surface (5/32 in.); Note: 3/16 in. comer crack is acceptable. 40. Acceptable porosity (2 @ 1/16 in.) 41.c. Rejectable because of elongated discontinuities on the convex surface, 42.0 Acceptable, no discontinuities. 43.e Bends A and C are rejectable. Welder does not pass qualification test. 44.0 Appendix VI, item (8). 45.d_ Side 1 has overlap, elorigated surface porosity and undercut present. 46. (App VIL, item (7) page 7; discontinuity is porosity which is greater than 3/8 inch.) ‘Two locations of linear porosity have lengths that fall within one linear inch and their sum is greater than 3/8 inch. :Answer Key - VIW Sample Questions 1, a from sample; width is 0.75 inches 2. © from sample; thickness is 0.185 inches (some measure 0.193 inches) 3. b_ area =0.75 x 0.185 = 0.13875 in’; UTS = 11,030/0.13875 = 79,495.495 or 79,495 (I thickness from #2 was 0.193 inches then area = 0.75 x 0.193 = 0.14475 in’, UTS = 11,030/0.14475=76,200 psi) 4, & area = 1.000 x 0.120 = 0.12 square inches 5. ¢ UTS =13,080/0.12 = 109,000 6. d (App X1, section 1, Tests on plate, page 11, % inch max) 7. © (App LV, page 4, for wall thickness of 0.250; App XII, section 2, Tests on pipe, page 14, for less than 24 inch diameter, T of 1/8 inch to 2T or 0.50 inch.) 8. a from sample; the 4 porosity pockets measure 4/32, 2/32, 2/32, 2/32 for a total of 10/32 or 5/16 inch, which is less than the 3/8" maximum that Part B permits 9. 2 from sample; a convex weld of unequal legs; vertical eg is slightly greater than 7/16, and horizontal leg is 7/16 at left end. Minimum size of weld is 7/16 inch : 10.¢ from sample; a flat weld with equal legs; minimum size of weld is 5/16 inch neat right end 11. from sample; the 5 porosity pockets measure 3/32, 2/32, 4/32, 3/32, 2/32 for a total of 14/32 or 7/16, which is more than the 3/8" maximum that Part B permits 12.d_ from sketch; item is being measured with the 32nds scale 13. 0.762 inches x 25.4 = 19.3548 or 19.35 14,¢ 18.7 mm x 3.937 x 10° = 0.736219 or 0.736 (alternate method 18.7/25.4 = 0.736) 15.d A= 0.762 x 0.736 = 0.560832 or 0.561 in.” and A = 18.7 x 19.35 = 361.845 mm? 16.2 UTS =51,550/0.561 = 91,889.483 or 91,889 17.b from sketch; the 1/4 inch concave gage is correctly used 18.d__ from sketch; the weld is convex, and a concave gage is being used in error 19.d_ from sketch; the gage shows the reinforcement being measured is acceptable. The height of the other face reinforcement has not been determined.