Professional Documents
Culture Documents
Welding Inspection
1. Which of the following should be assessed as part of the welding quality control?
A. AWS D1.1
B. Codes and Standards
C. Welders work histories
3. List the four potential inspector actions associated with tasks prior to welding.
A._________________________________________________
B._________________________________________________
C._________________________________________________
D._________________________________________________
4. As part of a welding review the inspector must determine the competency of the
welding organization and the competency of the __________________________.
A. design engineer
B. welding foreman
C. inspection organization
5. Name three items that the inspector must assure are in order before accepting NDE
procedures.
A.___________________________________________________________
B.___________________________________________________________
C.___________________________________________________________
6. As regards storage ovens for welding consumables the inspector should confirm that
the ovens have ______________________________.
7. List the four issues that must be addressed when reviewing proposed heat treatment
and pressure tests.
A. _____________________________________________________________
B. _____________________________________________________________
C. _____________________________________________________________
D. _____________________________________________________________
4.2.7 Materials
8. All filler metals, base materials, and backing rings materials should be properly
marked and identified. What additional step might be required to insure proper
materials?
Ans. ____________________________________________________________
9. Preheat is often applied prior to welding; sometimes it may also be needed for
_____________.
A. bending pipe
B. thermal cutting
C. popping off scale in single vee welds
10. One item often forgotten during the review of welding consumables is looking for the
_______________.
11. Normally quality assurance and quality control measures include such things as
welder responsibility, welder qualification, and the welder understanding the
requirements of the WPS and inspection hold points. What else might be required to
help the welder perform the weld?
Ans. ____________________________________________________________
12 During the inspection of a weldment, tack welds, weld root penetration, cleaning
between passes, in-process rework, in process ferrite measurement if required and
final weld sizes will be required. What else might be necessary?
Ans. ________________________________________________________
13. Which of the following items should be assessed after completion of a weldment?
14. If performing NDE on a weldment that will receive PWHT the order of operation
is________________.
16. The hazards associated with welding that the inspector must be aware of
are_______________________________.
A. _____________________________________________________________
B. _____________________________________________________________
C. _____________________________________________________________
D. _____________________________________________________________
5 Welding Processes
A. It often uses pressure in combination with the welding arc to complete fusion and
assure complete penetration of the base material.
B. Only DC current can be used with the SMAW process.
C. A gas for shielding of the molten metal is generated by the decomposition of the
electrode covering.
18. The covering for and SMAW electrode provides a way to add alloys to change the
mechanical properties of the weld metal.
A. True
B. False
A. ______________________________________________________________
B. ______________________________________________________________
C. ______________________________________________________________
D. ______________________________________________________________
20. Name the two major limitations when using the SMAW process.
A. ______________________________________________________________
B. ______________________________________________________________
21. When using GTAW in DC current mode typically it will be set to DCEN polarity.
DCEN stands for________ and provides ____________________.
A. Continuous voltage
B. Constant voltage
C. Consistent voltage
24. The danger in using the short circuiting mode of arc transfer is _______________?
A. Spatter is minor
B. Spatter is a major concern.
C. It cannot be used in any mode for thin sheet material.
29. The slag generated by the FCAW process has the advantage of _________.
31. List the two advantages that SAW has over other processes.
A. ______________________________________________________________
B. ______________________________________________________________
33. _____ current is normally used with SW and its positions allowed are______.
5.7.2 Limitations of SW
5 Welding Processes
Equipment Identification
9 NON-DESTRUCTIVE EXAMINATIONS
9.1 DISCONTINUITES
41. The _________________ should choose the NDE method based on the type of
discontinuity and weld joint.
A. NDE Examiner
B. Welding foreman
C. Inspector
Table 4 - Capability of the Applicable Inspection Method for Weld Type Joints
44. Which method of the following NDE methods is applicable to all weld type joints?
A. RT
B. UT
C. PT
A. Leak Testing
B. Longitudinal ACFM
C. Laser Testing
A. True
B. False
47. Which of the following welding processes does not promote hydrogen cracking in
carbon steel welds?
A. SMAW
B. FCAW
C. SAW
D. GTAW
48. If a weld is found to have excessive undercut at the toe the best way to detect it is
by ______ or _______, and the best way to correct undercut is to _________ during
welding.
50. The GMAW -S (short circuiting mode) is subject to the discontinuity Lack of
Sidewall Fusion. Which of the following might help with this problem?
A. The inspector
B. The product manufacturer
C. The owner/user
57. Visual examination personnel are required to pass a vision test _________ and it
shall be of the __________________ eye vision test.
59. On of the most common and popular flux direction indicator for MT is known as the
________.
A. Cake gauge
B. Pie gauge
C. Donut gauge
9.4.3 Demagnetization
61. The maximum temperature that the ACFM method can be used at is _________.
A. 900 oF
B. 600 oF
C. 482 oF
62. ACFM does not require the use of a calibration piece with artificial flaws.
A. True
B. False
63. List below the uses for eddy current testing in welding inspection.
A. ____________________________________________________
B. ____________________________________________________
C. ____________________________________________________
D. ____________________________________________________
66. Which weld thickness below is best suited for use with Iridium 192 source?
A. 0.500
B. 3.5
67. As regards film processing, the normal development time is listed as 5 to 8 minutes
at ________.
A. 82 oF
B. 70 oF
C. 68 oF
Ans. _______________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
__________________________________________________________________
70. The minimum number of radiographic exposures when using the single-wall viewing
on circumferential welds is ______.
A. 2
B. 3
C. 1
A. True
B. False
A. cracks
B. cracks, lack of fusion
C. cracks, lack of fusion or overlap
A. too high a magnification will distort the size of an indication and may cause undue
rejection
B. too high a magnification will enhance the graininess of the film
74. Clear film has a density of 0, a film that allows 10% of the incident light pass through
has a density of 1.0. A film that allows 1% pass through has a density of
___________.
A. 3.0
B. 2.0
A. LOP
B. centerline cracking
A. random
B. cluster
77. This radiograph indicates burn through. According to Table 6 of RP 577 this was
probably not welded using the _______________process.
A. SMAW
B. GMAW
C. GTAW
D. FCAW
A. B-scan
B. C-scan
C. A-scan
D. D-scan
A. cross-sectional
B. planner
C. half thickness
A. C-scan
B. B-scan
C. A-scan
82. Some requirements are placed on the condition of a calibration block for use with
UT. List those requirements below.
A. ______________________________________________________________
B. ______________________________________________________________
C. ______________________________________________________________
D. ______________________________________________________________
E. ______________________________________________________________
84. Match the following descriptions with the method it applies to.
1. Very effective for sizing flaws which are open to the inside or outside diameter
surface and are shallow to mid-wall. ____
2. Uses the effects of multiple sound modes, such as longitudinal waves and shear
waves to qualitatively size flaws. ____
3. A dual element tandem probe with the transducers crystals located one in front of
the other. ____
4. Wave method that is very effective for very deep flaws. _____
85. Hardness tests on welds are meant to verify that acceptable softness has been
maintained after welding and often is applied after any required heat treatment. The
places where the hardness tests are performed are ______________________.
87. _______________ largely responsible for the physical and mechanical properties
of metal.
88. Wrought materials are those which have been worked by ____________________.
A. rolling
B. forging
C. extrusion
D. All of the above
89. Weld metal does not have the same uniform makeup as the base metal, because
________________________________________.
90. The heat affected zone (HAZ) of a weldment is an area that has not been melted but
has been affected by the pre-heat and heat of welding. For carbon steels this occurs
at temperatures _____________________.
91. A pure metal has a fixed melting temperature that is just above its solidification
temperature. However, complete melting of _________occurs over a range of
temperatures.
A. non-ferrous metals
B. alloyed materials
C. ferrous metals
92. Which property below affects the heat input required to weld a metal?
93. Steel requires less heat input to weld than aluminum. What property determines
this?
A. Thermal Conductivity
B. Electrical Conductivity
C. Density
94. Some metals are more subject to distortion than others during welding. This is
because of a physical property know as _______________________
A. Electrical Conductivity
B. Coefficient of Thermal Expansion
C. Thermal Conductivity
95. Casting and welds are usually _______dense than wrought materials.
A. more
B. less
A. Thermal Conductivity
B. Density
C. Melting Temperature
97. The mechanical property of a metal that defines its amount of deformation and
elongation is referred to as _____.
A. ultimate strength
B. tensile strength
C. strain
A. tensile strength
B. the extent to which a metal can be worked without fracture during fabrication
operations
C. how often a metal can be stressed before failure
A. Vickery C
B. Knoop
C. Donnell Scale
100. Which hardness test uses a minor and major load to determine hardness?
A. Rockwell
B. Vickers
C. Brinell
101. The ability for a metal to absorb energy and deform plastically before fracture is
known as its ___________________.
A. Ductility
B. Yield
C. Toughness
A. spider cracking
B. planer breaking flaws
C. brittle fracture
103. Which of the following is the primary reason for pre-heating when welding carbon
and low alloy steels?
10.7 HARDENING
105. Which of the following is a typical test for the hardenability of metals?
106. Which of the following is not a true statement about the MTR?
A. The chemical analysis given in the test report can be used to calculate the carbon
equivalent for that material.
B. The inspector should review the material test report.
C. The material test report is automatically provided by the manufacturer even if not
requested.
A. ______________________________________________________________
B. ______________________________________________________________
C. ______________________________________________________________
D.______________________________________________________________
E. ______________________________________________________________
A. easier to weld
B. more difficult to weld
A. sulfur
B. phosphorus
C. arsenic
D. all of the above
A. Schaffer
B. Dilution
C. Carbon Equivalent
111. The restraint tests that determine possibility of weld metal cracking for the following
locations and types are ____________________.
Solidification cracks
Root & Toe
Micro cracks
112. List the most important considerations when welding Stainless Steels.
A. _______________________________
B. _______________________________
C. _______________________________
D. _______________________________
113. Austenitic stainless steels are iron-based alloys that typically contain low carbon,
chromium between ________ and nickel between _________.
114. Stainless Steels which are subject to hot cracking may be evaluated for this
problem by using the __________________________.
115. Austenitic Stainless Steels distort more easily than carbon steels due to their lower
__________ and higher_____________.
116. Nickel alloys weld in a sluggish manner, meaning the weld metal does not move
easily during the welding process and this tends to create a lack of sidewall fusion
as a result. A proper technique is to use a weave or oscillation during welding.
One indication that proper weave/oscillation has not occurred is
______________________.
A. short cracks
B. hot cracking
C. cold cracking
118. The two primary concerns when welding on in-service piping and equipment are
____________ and __________.
119. Hot tap and in-service welding should be carried out only with low - hydrogen
consumables, the reasoning for this when welding carbon steel is to
prevent___________.
120. The flow rate of liquids in a piping system may affect the possibility of a failure
during in-service welding. A low flow rate may cause____________.
121. When hot tapping a piping system that contains Wet Hydrogen Sulfide the
possibility of __________________ is a concern.
A. explosion
B. pyrophoric scale
C. metal burning
11.2.4 Inspection
122. Briefly list the duties of the inspector associated with hot tapping or welding on in-
service equipment.
A. ______________________________________________________________
B. ______________________________________________________________
C. ______________________________________________________________
D. ______________________________________________________________
E. ______________________________________________________________
F. ______________________________________________________________
G. ______________________________________________________________
H. ______________________________________________________________
123. In the Edge Joint depicted above which of the following types of welds
unacceptable?
A. Bevel Groove
B. U - Groove
C. Plug
126. Using Figure A-4 label the element of the drawing above.
AWS
Filler Metal Classifications
A. Tubular
B. Position
C. Trailing gas required.
130. A good choice of filler metal for the SMAW welding of carbon steel to carbon
molybdenum steel might be _______ and ________.
131. List below the common welding consumables to weld 304L Stainless Steel to
Carbon Steel.
A. __________
B. __________
132. A common filler metal in the past for welding 1Cr -1/2 Molybdenum was E8018-
B2L, that AWS classification has been changed to _________________.
1. C
2. B
3. A. Identify and clarify missing details and information.
B. Identify and clarify missing weld sizes, dimensions, tests, and any additional
requirements.
C. Identify and clarify inconsistencies with standards, codes and specification
requirements.
D. Highlight potential weld problems not addressed in the design.
4. C
5. A. NDE examiners are properly certified for the NDE technique (see 4.6)
B. NDE procedures are current and accurate.
C. Calibration of NDE equipment is current.
6. C
7. A. Heat treatment procedure is available and appropriate (see 10.6).
B. Pressure testing procedures are available and detail test requirements.
C. PWHT equipment calibration is current.
D. Pressure testing equipment and gauges calibrated and meet appropriate test
requirements.
8. Ans. If required, perform PMI to verify the material composition
9. B
10. C
11. Ans. Special training and mock-up weldments performed if required.
12. Ans. - Additional NDE performed between weld passes and on back-gouged
surfaces.
13. B
14. A
15. A
16. A. Arc radiation
B. Air contamination
C. Airborne debris
D. Heat
17. C
18. A
19. A. Equipment is relatively simple, inexpensive, and portable.
B. Process can be used in areas of limited access.
C. Process is less sensitive to wind and draft than other welding processes.
D. Process is suitable for most of the commonly used metals and alloys
20. A. Deposition rates are lower than for other processes such as GMAW.
B. Slag usually must be removed at stops and starts, and before depositing a weld
bead adjacent to or onto a previously deposited weld bead.
21. C
22. C
23. B
24. C
25. B
26. A
27. B
28. B
29. A
30. C
31. A. Provides very high metal deposition rates.
B. Produces repeatable high quality welds for large weldments and repetitive short
welds.
32. A
33. B
34. C
35. SMAW
36. GTAW
37. GMAW
38. FCAW
39. FCAW self-shielding
40. SAW
41. C
42. C
43. B
44. C
45. A
46. A
47. D
48. C
49. C
50. D
51. Seam or Lap
52. Throat Crack
53. Overlap
54. Aligned Porosity
55. Incomplete Fusion
56. C
57. C
58. D
59. B
60. A
61. A
62. A
63. A. Eddy current can be used as a quick test to ensure that the components being
joined during welding have the same material properties.
B. As a quick check for defects of the weld joint faces.
C. Measure the thickness of protective, nonconductive surface coatings.
D. Measure cladding thickness.
64. B
65. B
66. A
67. C
68. C
69. Ans. For materials, and for welds in components, a technique may be used in
which the radiation passes through two walls and only the weld (material) on
the film sidewall is viewed for acceptance. An adequate number of exposures
should be made to demonstrate that the required coverage is met for
circumferential welds (materials). A minimum of three exposures taken at
120 to each other should be made.
70. B
71. B
72. C
73. B
74. B
75. A
76. B
77. C
78. C
79. A
80. A
81. C
82. A. (calibration block) should be of the same nominal diameter
B. Same thickness.
C. Same composition.
D. Same heat treatment condition as the product that is being examined.
E. It should also have the same surface condition as the part being examined.
83. C
84. 1. B
2. A
3. D
4. C
85. B
86. B
87. C
88. D
89. C
90. A
91. B
92. C
93. B
94. B
95. B
96. B
97. C
98. B
99. B
100. A
101. C
102. C
103. B
104. A
105. B
106. C
107. A. The metallurgical compatibility of the metal or alloy being welded, which is
related to the chemical composition and microstructure of the metal or alloy,
and the weld filler metal used.
B. The specific welding processes being used to join the metal.
C. The mechanical properties of the metal, such as strength, ductility and
toughness.
D. The ability of the metal to be welded such that the completed weld has sound
mechanical properties.
E. Weld joint design.
108. B
109. D
110. C
111. A
112. The most important considerations to welding austenitic stainless steels are;
A. solidification cracking
B. hot cracking
C. distortion
D. maintaining corrosion resistance
113. C
114. B
115. B
116. C
117. B
118. A
119. C
120. B
121. B
122. Inspection tasks typically associated with hot tapping or welding on in-service
equipment should include:
A. Verifying adequate wall thickness along the lengths of the proposed welds
typically using UT or RT.
B. Verifying the welding procedure. Often, plants have welding procedures
qualified specifically for hot taps and in-service welding.
C. Verifying flow conditions.
D. Specifying the sequence of welding full encirclement sleeves and fittings