Professional Documents
Culture Documents
1.
2.
(a) SAW
(b) TIG
(c) MIG / MAG
(d) MMA
One of the advantages of a multi-pass MMA weld is that it generally produces a:
(a)
(b)
(c)
(d)
3.
MMA electrode can be grouped into three main types. These are:
4.
5.
6.
The core wire in a MMA electrode has a higher melting point than the flux
Electrode dc +ve is used when welding with the MIG / MAG welding process
The HAZ of a carbon manganese steel weld usually has a lower ultimate tensile strength than the weld
All of the above are true
A multi run MMA butt weld made on C/Mn steel consists of 5 passes using 6mm electrodes. A 12 pass weld
made on the same joint using 4mm electrodes on the same material will:
(a)
(b)
(c)
(d)
7.
Arc deviation
Arc misalignment
Arc blow
Arc eye
A typical minimum preheat temperature for an MMA weld made on steel with a carbon content of 0.23% and
manganese content of 1.3%:
(a)
(b)
(c)
(d)
8.
Which is often the hardest part of a multi run weld made using MMA?
9.
10.
(a)
(b)
(c)
(d)
11.
Which of the following welding processes uses a resistive heating system to achieve weld metal deposition?
12.
(a) MMA
(b) SAW
(c) Electro slag welding
(d) Resistance spot welding
In MMA welding, what parameter is used to control the penetration into the base material?
13.
14.
(a) Voltage
(b) Welding speed
(c) Iron powder in the coasting
(d) Current
In MMA welding, the slag produced can be varied to suit the welding position. Which type of slag would be
required for welding in the HV position?
(a) Fluid
(b) Viscous
(c) None of the above
(d) Semi fluid
The weld metal deposit of MMA electrodes, achieves its mechanical strength through:
(a) The core wire
(b) The flux coating
(c) Iron powders with the flux coating
15.
16.
Which arc welding process technique is likely to be used to repair localized porosity in a weld?
(a)
(b)
(c)
(d)
(e)
17.
Short electrode length, the control of the arc length and the process uses a flat characteristic
Short electrode length, the control of the arc length and flux coverings
The control of the arc length, stop start problems and short electrode length
Flux coverings, short electrode lengths and relationship between amps and volts
MMA PG position
Mechanised arc welding
Sub Arc
All of the above
None of the above
A repair has been made using MMA on a double V butt weld on a 10 m diameter tank. The defect repaired was
lack of inter-penetration and it had been excavated with a disc grinder prior to repair. After repair it was
determined that the wrong electrodes had been used. What action should the inspector take:
(a)
(b)
(c)
(d)
18.
19.
TIG
MIG
MAG
All of the above
20.
21.
22.
(a) Voltage
(b) Amperage
(c) Polarity
(d) None of the above
Why have a high OCV with MMA welding?
(a)
(b)
(c)
(d)
23.
To initiate
To obtain penetration
To avoid lack of fusion
MMA welding does not have a high OCV
Which of the following sentences applies to the use of basic MMA electrodes?
(a)
(b)
(c)
(d)
24.
They are used to deposit weld metal in the vertical position only
They are used where deep penetration is a primary requirement
They are usually used to deposit weld metal of low hydrogen content
Basic electrodes are chosen when ease of use is of importance
Which of the following welding processes does not use a consumable electrode?
a
b
c
d
1.
SAW
MMA
TIG
ESW
Which of the following welding processes may be described, as a low hydrogen process in comparison with general MMA
welding:
2.
a)
TIG
b)
MIG
c)
MAG
d)
None of the above
e)
All f the above
Why have a high O.C.V. with MMA welding
3.
a)
To initiate the arc
b)
To obtain penetration
c)
To avoid lack of fusion
d)
MMA welding does not have a high O.C.V.
Fish eyes, chevron cracks and fissures are:
a)
b)
c)
d)
4.
Which of the following butt-weld preparations is generally most susceptible to lack of side wall fusion during MMA
welding?
a)
b)
c)
A U preparation
A V preparation
A double V preparation
5.
d)
Lack of side wall fusion does not exist with MMA
Which welding process is considered the most versatile?
a)
b)
c)
d)
6.
When welding using the MMA process, varying the arc length will give the most variation of:
a)
b)
c)
d)
7.
8.
9.
SAW
TIG
MIG/MAG
MMA
Voltage
Amperage
Polarity
None of the above
Which defect would you expect to obtain in TIG welds in non-deoxidized steel?
a)
Under cut
b)
Porosity
c)
Tungsten inclusions
Linear misalignment You noticed manual metal arc welding electrodes, stripe 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 weld metal composition may be wrong
The wire is too short When the TIG welding Austenitic Stainless Steel pipe. Argon gas backing is called for.
This is to:
a)
Prevent oxidation
b)
Prevent under bead cracking
c)
Prevent porosity
d)
Control the penetration bead shape
10. When referring to TIG welding, the shielding gas could be:
d)
Argon + Hydrogen
e)
Argon + Helium
f)
Argon + Nitrogen
g)
All of the above
11. Which arc welding process utilizes a non-consumable electrode?
h)
MIG
i)
TIG
j)
MMA
k)
SAW
l)
All of the above
12. Which
of
the
system of fusion?
a)
b)
c)
d)
13.
following
processes
uses
the
Friction welding
Diffusion bonding
Electron beam welding
Autogenous TIG welding
Argon purging on the root side is necessary in the TIG welding of stainless steel to:
a. Obtain full penetration.
b. Obtain full fusion.
c. Avoid porosity in the root.
d. Obtain a satisfactory weld surface finish.
13. Two low carbon steel pipes, 150mm diameter and 6mm wall thickness, are to be butt welded
using the TIG process. To ensure a full strength joint, which of the following preps is most
suitable?
a. Open single bevel.
b. Open single Vee.
keyholing
14. Which of the following defects is more common to welds deposited by CO2 welding than
welds deposited by MMA?
a. Slag inclusions.
b. Excess penetration.
c. Lack of sidewall fusion.
d. Tungsten inclusions.
TIG
25.
26.
27.
28.
29.
(a) Copper
(b) Aluminum
(c) Ceramic
(d) Copper / Zinc
Which arc welding process uses a non consumable electrode?
30.
(a) MIG
(b) TIG
(c) SAW
(d) None of the above
Which of the following current types would be used for welding aluminum with the TIG welding process?
(a) Ac
31.
32.
(a)
(b)
(c)
(d)
It is too expensive
The wire would be too thick
The weld metal composition may be wrong
The wire is too short
When TIG welding Austenitic Stainless Steel pipe, Argon gas baking is called for. This is to:
Prevent oxidation
Prevent under bead cracking
Prevent porosity
Control the penetration bead shape
33.
The main reason for using a back purge when welding 18-8 stainless steel with the TIG welding process is to:
(a)
(b)
(c)
(d)
MIG
1.
In MIG ? CO2 welding which parameters give the greatest control of weld appearance during dip transfer or
short circuiting welding?
(a)
(b)
(c)
(d)
34.
35.
36.
Which of the following processes would be most prone to lack of fusion defects:
(a)
(b)
(c)
(d)
37.
Adjusting the inductance control in dip transfer MIG / MAG welding, will control:
(a) The pulse rate
(b) The gas flow rate
(c) The amount of spatter
MIG welding tends to be susceptible to lack of fusion problems. This is because of:
(a)
(b)
(c)
(d)
38.
A common gas / mixture used in MIG welding nickel alloys to combine good levels of penetration with good
arc stability would be:
(a)
(b)
(c)
(d)
39.
40.
100 % CO2
100% Argon
80% Argon 20% CO2
98% Argon 2% Oxygen
41.
Joint set up, flux coating, polarity, travel speed and amps / volts
Amps / volts, WFS, gas flow rate, polarity and travel speed
Amps / volts, WFS, wire diameter, polarity and travel speed
Electrode stick out, WFS, amps / volts, polarity and wire diameter
Saw
42.
When welding a double V butt with the SAW process the presence of center line porosity may be due to:
e
Damp flux
f
Incomplete penetration
g
Contaminated weld preparation
h
Atmospheric contamination
The type of SAW flux is more resistant to moisture absorption:
a
b
c
d
43.
When welding a double V butt joint with SAW process the presence of centerline porosity may be due to:
(a)
(b)
(c)
(d)
44.
Fused
Agglomerated
Basic
All of the above the same resistance
Damp flux
Contaminated joint preparation
Incorrect stick out lengths
All of the above
45.
46.
47.
48.
If Submerged arc welding is to be used to make butt welds, which would you be most critical of?
(a)
(b)
(c)
(d)
49.
50.
51.
52.
53.
54.
(a) BS 639
(b) BS 2901
(c) BS 2633
(d) BS 4165
In submerged arc welding, excessive arc voltage may cause?
a)
Excessive penetration
b)
Change in weld metal composition
c)
Narrow weld width
d)
Excessive bead profile
Slag inclusion would occur with:
a)
Manual metal arc
b)
Metal inert gas
c)
Submerged arc welding
d)
Both A & C
A metallurgical problem most associated with submerged arc welding is:
a)
b)
c)
d)
Submerged arc
CO2 (metal active gas)
Manual metal arc
Tungsten inert gas
1.
A common gas mixture used in MIG welding nickel alloys to combine good levels of penetration with good
arc stability would be:
2.
a)
100% CO
b)
100% argon
c)
80% argon 20% CO2
d)
98% argon 2% oxygen
The type of SAW flux is more resistance to moisture absorption:
3.
a)
Fused
b)
Agglomerated
c)
Basic
d)
All of about the same resistance
When referring to MIG welding, the shielding gas could be:
4.
5.
a)
Argon
b)
Argon + 1% Oxygen
c)
Argon + 20% CO2
d)
None of the above
The steel composition in structural contract is changed form 0.15% carbon, 0.6% manganese, to 0.2% carbon,
1.2% manganese. Might this influence the incidence of?
a)
Porosity
b)
Cracking in the weld area
c)
Under cut for fillet welds
d)
Lack of root fusion defects
MIG welding tends to be susceptible to lack of fusion problems. This is because of:
a)
b)
c)
d)
6.
Pre heat
1.
In accordance with BS 5135 what is the minimum distance the pre heat shall be applied from the joint
preparation?
(a)
(b)
(c)
(d)
55.
56.
100 mm
25 mm
75 mm
Not specified
In accordance with BS 5135 what is the recommended minimum time allowed for the pre heat temperature to
equalize?
(a) 2 Min for each 25 mm of parent material thickness
(b) 5 Min for each 25 mm of parent material thickness
(c) 2 Min for each 50 mm of parent material thickness
5 Min for each 50 mm of parent material thickness Applying preheat when welding, carbon manganese steel is
normally done to avoid:
(a) Slag inclusions
57.
58.
How many temperature indicating crayons would be required to ensure the preheat temperature was lying
within a specified range?
(a)
(b)
(c)
(d)
1.
1
2
3
As many as possible
Is hig for a C-Mn steel and may require a preheat temperature over 100*c
Is insignificant for a C-Mn steel and preheat will not be required
Is calculated from the heat input formula
Is not a consideration for determining preheat temperature
2.
59.
60.
Electrode
1.
2.
(a) Cellulosic
(b) Titanium dioxide
(c) Calcium carbonate
(d) Asbestos
What does the 70 represent on a E 7010 AWS classified electrode?
3.
(c) Rutitle
(d) None of the abobe
61.
When H2 control is specified for a manual metal arc welding project, the electrode would normally be:
62.
(a) Cellulose
(b) Iron oxide
(c) Acid
(d) Basic
You would with certainty recognize a hydrogen controlled flux covered electrode from its:
63.
(a) Colour
(b) Length
(c) Trade Name
(d) AWS / BS639 Code Letter
In BS 639 and BSEn 499 the first digits of the electrode classification indicate:
64.
65.
66.
67.
E 6013
E 5133
E 7018
Fleet weld 5
Has an UTS value of 51,000 psi, minimum yield strength of 330 N/mm
Has an UTS value of 430 to 550 N/mm, minimum yield strength of 360 N/mm
Has an UTS value of 510 to 650 N/mm, minimum yield strength of 360 N/mm
Has an UTS value of 510 to 650 N/mm, minimum yield strength of 330 N/mm
68.
69.
(a) BS EN 499
(b) BS 639
(c) AWS A5.5
(d) AWS A5.1
What types of electrodes needs extra treatment?
(a) Basic
(b) Rutile
(c) Cellulosic
70.
71.
What constituent is needed in a coating of an electrode to prevent the formation of porosity in welding of a
rimming steel?
(a) Iron powders
(b) Calcium fluoride
(c) Silicon
(d) Calcium carbonate
The use of cellulosic electrodes is often made when welding the root pass of pipes in the field. This is because:
(a)
(b)
(c)
(d)
Hydrogen
72.
H2 control is needed
Iron powders in the electrode
Higher arc voltage can be obtained
Shorter arc length can be achieved
The presence of too much hydrogen when welding C/Mn steels would be to cause the formation of:
i
Porosity
j
Lack of fusion
k
Crack
l
undercut
Hydrogen cracking in the weld metals is likely when welding:
a
Carbon Manganese steels
b
Stainless steels
c
Micro alloyed steels (HSLA)
d
Low carbon steels
In accordance with BS 5135 which of the following is applicable for scale C with regards to hydrogen
content per 100g of deposited weld metal?
a
b
c
d
> 15 ml
> 15 ml < 25 ml
> 10 ml < 15 ml
> 5 ml < 10 ml
Solidification
1.
Name the fourth weld process crack which has a totally different formation mechanism to HICC (H2 induced
cold crack), solidification cracking and lamellar tearing:
(a)
(b)
(c)
(d)
Undercut
1.
73.
Excessive amps
Excessive volts
Excessive travel speed
All of the above
Overlap
1.
Liquation cracking
Reheat cracking
Crater cracking
Hot tearing
Its depth
Its length
Its blending
All of the above
(a)
(b)
(c)
(d)
Ultrasonic
1.
74.
Ultrasonic testing is of advantage in detecting which of the following weld imperfection over other NDT
method:
(a)
(b)
(c)
(d)
Tempering
1.
The process of tempering is often carried out to regain toughness after which of the following processes:
2.
(a) Annealing
(b) Normalising
(c) Hardening
(d) Stress relieving
When considering the heat treatment process of tempering:
3.
(a) This is achieved by slowly heating the material to a temperature between 200*c to 650*c and slow
cooling in air
(b) This is achieved by heating the material to around 200*c and soaking for approximately 10 12 hrs and
cooling down in air
(c) Very fast cooling form the austenite region
(d) All of the above could give a temper
Re-crystallization during annealing is used to make steel:
(a)
(b)
(c)
(d)
Softer
Harder
Tougher
Stronger
Quenching
1.
When a medium to high carbon steel is quenched:
(a)
(b)
(c)
(d)
It becomes malleable
Its hardness increases
It becomes ductile
The plasticity is increased
Normalizing
1.
A Normalising heat treatment process is carried out by:
(a) Heating the metal just above 650*C
(b)
Taking the metal above the re-crystallization temperature and allowing to air cool
(c)
Taking the metal above the re-crystallization temperature and allowing to furnace cool
(d)
Taking the metal above the re-crystallization temperature and quickly cooling by immersing
Visual inspection
1.
The British code for visual inspection requirements is:
(a) BS 4872
(b) BS 499
(c) BS 4870
2.
3.
Up to 50
2 2.5
50 100
None of the above
75.
76.
Tensile
1.
2.
77.
BS 4515
BS 5289
BS 5135
BS EN 440
Impact values
Stress
Strain
Both B & C
Which of the following in a fusion weld usually has the highest tensile strength?
(a)
(b)
(c)
(d)
Weld metal
Parent material
HAZ
Fusion zone
Weldability
1.
The weldability of a material may be affected by:
2.
Oxy fuel
1.
(a)
(b)
(c)
(d)
78.
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?
(a)
(b)
(c)
(d)
79.
2.
Fatigue
1.
Oxy pressure and nozzle size would influence what in flame cutting:
(a)
(b)
(c)
(d)
80.
3200* C
2300* C
5000*C
None of the above
Travel speed
1.
81.
The welder is responsible for the arc gap and travel speed
The welder is responsible for the travel speed only
The welding plant controls both travel speed and arc gap but under constant supervision
The welding plant controls both travel speed and arc gap, no supervision required
Lamellar tearing
1.
Which of the following are essential factors for lamellar tearing?
(a) High residual stresses, poor through thickness ductility, existing plate Laminations
(b) Poor through thickness ductility, fusion face parallel with rolled direction of parent plate, most
commonly occurs in but welds
(c) Stress, poor through thickness ductility, fusion face parallel with rolled direction of parent material
2.
(d) Tensile stress, deoxidized parent plate, poor through thickness ductility
What is lamellar tearing?
3.
82.
Lamellar tearing:
(a)
(b)
(c)
(d)
Cold lap
1.
2.
X-ray examination
Dye penetrant
Ultrasonic inspection
It would not have been found by any inspection method
Lack of fusion
Low amperage
Undercut
Hydrogen cracking
Heat input
1.
What are the possible results of having a too lower heat input?
(a)
(b)
(c)
(d)
83.
Welds made with high heat inputs show a reduction in one of the following properties:
(a)
(b)
(c)
(d)
84.
Ductility
Toughness
Fatigue strength
Mechanical strength
Welding procedures may require welds to be deposited at a controlled rate heat input. High heat input would:
(a)
(b)
(c)
(d)
85.
Which is the correct heat input if the amps are 350, volts 32 and travel speed 310 mm / s?
(a) 2.16 kJ / mm
(b) 0.036 kJ / mm
(c) 2160 kJ / mm
(d) 36 kJ / mm
Mechanical test
1.
2.
Bend test specimens have been taken from a 25mm thick carbon steel butt weld. Which would show lack of
inter-run fusion:
(a) Side bend
(b) Root bend
(c) Face bend
(d) Guided bend
Internal lack of fusion defects can be normally found by using:
(a)
(b)
(c)
(d)
86.
Penetrant testing
Impact tests
Side bend test
Hardness test
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:
87.
88.
(a) Macro
(b) Nick break
(c) Hardness
(d) Charpy vee notch
What is a charpy test used for?
(a) To measure the ductility of a material
(b) To test the tensile strength of a material
(c) To test the notch toughness of a material
(d) to measure crack propagation speed
1.
89.
90.
When the run out date of the procedure has been reached
Every Year
When changing from day to night shift work
When there is a change in an essential variable
1.
Defect
1.
2.
3.
(a) Repaired
(b) Reported to a senior person
(c) Radio graphed
(d) All of the above
Stray arcing may be regarded as a serious defect. This is because:
(a)
(b)
(c)
(d)
91.
92.
93.
(a) Planar
(b) Cracks
(c) Lack of fusion
(d) All of the above
Which of the following NDT method is not suitable to detect sub surface defect?
(a)
(b)
(c)
(d)
94.
95.
UT
PT
RT
MPI
The hardest grain structure capable of being produced when welding C/Mn steel is:
e
Bainite
f
Austenite
g
Pearlite
h
Martensite
Which of the following steel structures has the highest hardness:
a
Martensite
b
Austenitic
c
Ferritic
d
All have the same hardness
The extent of the changes in microstructure will depend on the following:
a
Material composition
b
Heat input
c
The rate of cooling
d
All of the above
A large grain structure in steels said to produce:
a
b
c
d
97.
The HAZ associated with a fusion weld on steel has up to how many separate regions of micro structure?
(a)
(b)
(c)
(d)
98.
4
6
1
2
A martensite grain structure:
If arc strikes are found on carbon steel (C eq of .5%), what undesirable grain structure may be present?
(a)
(b)
(c)
(d)
(e)
Perlite
Martensite
Bainite
All of the above are undesirable grain structures in constructional steels
Crater pipe
1.
If arc strikes are found on carbon steel (C eq of .5%), what undesirable grain structure may be present?
2.
(a) Perlite
(b) Martensite
(c) Bainite
(d) All of the above are undesirable grain structures in constructional steels
Which of the following is an alternative name for a crater crack?
(a)
(b)
(c)
(d)
Radio gragh
Cold crack
Tearing
Star crack
Fatigue crack
1.
99.
100.
Image quality
Type of steel
Density of graph
Type of welding process used
Degrease
1.
2.
The main reason degreasing agents should always be dried from metals prior to welding, is because they are
likely to:
(a) Increase the arc voltage
(b) Produce hazardous fumes
(c) Slow down the welding speed
(d) Produce lack of fusion defects
Degreasing components are essential for quality welding but some agents may:
(a) Cause corrosion problems
(b) Give off phosgene gas
(c) Leave residues
Carbon
1.
2.
3.
101.
Porosity
Cracking in the weld area
Undercut for fillet welds
Lack of root fusion defects
Pre-heating a carbon steel manual metal arc welding is carried out to minimize the risk of:
(a)
(b)
(c)
(d)
Scattered porosity
Worm hole porosity
Parent metal cracking
Lack of penetration
102.
Pre-heating a carbon steel manual metal arc welding is carried out to minimize the risk of:
(a)
(b)
(c)
(d)
Harden
1.
2.
Scattered porosity
Worm hole porosity
Parent metal cracking
Lack of penetration
Which of the following chemical elements has the greater effect on the hardenability of a steel plate?
(a) Molybdenum
(b) Chromium
(c) Titanium
(d) Carbon
To prevent the hardening and cracking of High Carbon Steel plate when flame cutting it is advisable to:
Which of the following welding processes is not classed as an arc welding process?
(a)
(b)
(c)
(d)
(e)
103.
Which of the following heat treatment processes would be used for grain refinement?
104.
(a) Annealing
(b) Normalizing
(c) Quenching
(d) H2 release
Which of the following welding processes is not a fusion welding process?
105.
106.
107.
Friction welding
Diffusion welding
Electron beam welding
Autogenous TIG welding
108.
Centreline
1.
Thermit welding
Electro slag welding
Laser welding
Friction welding
You observe centerline cracking in a weld that has been made at one of five work station each making similar
components. The first action to take is:
(a)
(b)
(c)
(d)
Weld symbol
1.
Weld symbols placed on a dotted line in accordance with ISO requirements means:
2.
(b)
10
10
(c)
10
10
(d)
1.
Porosity
1.
This or arrow side of the joint goes on top of the reference line
This or arrow side of the joint goes below the reference line
This or arrow side of the joint goes in the middle of the reference line
All of the above
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
Day temperature
109.
110.
111.
Poor access
Loss of gas shield
Dirty materials
All of the above
Discontinuity
1.
Which of the following discontinuities could be as a primary processing discontinuity often found in cast
material?
(a)
(b)
(c)
(d)
Fatigue crack
Stress corrosion crack
Porosity
Lack of penetration
112.
113.
(b) Laps
(c) Cold shuts
(d) Insufficient penetration