CSWIP 3.2.

2 - March 2019

Welding Inspection Refresher Assessment

1. Which of the statement is true about Weld Decay?

It is result of Cr Carbide formation.
2. Which of the statement is true about Hydrogen Cracking?
for this happen it is requires a stress level half or greater than the parent material yield strength is to be present.
3. Which of the statement is true about codes and statements?
ISO 2560 is for covered Electrodes
4. Which of the statement is true about Radiographic Testing?
Penetrating Radiation ( X ray ) is created by High Energy Electrons Beams
5. Which of the statement is true about in MMA welding?
DC negative is one third of the heat energy is in the Electrode.
6. Which of the statement is true about for MIG / MAG welding?
Stainless Steel Liners are generally used for Stainless Steel.
7. Which of the statement is true about MAG welding?
It Has Tendency to cause Lack of fusion in the PF position when using Dip Transfer.
8. Which of the statement is true about TIG welding?
If current is increased the Penetration Increases.
9. Which of the statement is true about Heat Treatment?
Post Hydrogen is release approximately 250 degree in accordance with EN standards.
10. For an Electrode designated E46 3 1Ni B 5 4 H5?
5 means current type
11. Which of the statement is true about weld decay?
It forms in the parent material between 600® to 850 ® C
12. Which of the following is Hydrogen cracking more prevalent in?
Carbon steels
13. Which of the statement is true about codes and statements?
BS EN ISO 15614 is for WPQRs
14. Which of the statement is true about RT?
Lack of side wall fusion is not easily detected with RT.
15. Which of the statement is true about arc blow in MMA welding?
Alternative current is not susceptible. Unlike DC positive and negative.
16. Which of the statement is true about MAG welding?
When voltage increases, penetration degreases.
17. Which of the statement is true about MIG welding?
Solid wires are always used.
18. Which of the statement is true about TIG welding?
Slope up prevents burn through.
19. Which of the statement is true about mechanical Testing?
Lateral expansion is a term you may expect to hear used in conjunction with impact testing.
20. Which of the statement is true about electrodes?
E7016 electrodes are low hydrogen.
21. Which of the statement is true about weld decay?
It may occur in 18 Cr 8 Ni.
22. Which of the statement is true about hydrogen cracking?
It always happened at around ambient temperature.
23. Which of the following is Regulatory authority for?
Preparing or adopting regulations.
24. Which of the statement is true about RT?
Gamma does not require a Power source.
25. Which of the statement is true about MMA welding?
Alternative current has 50-60 cycles per second.
26. Which of the statement is true about MIG/MAG welding?
When electrode extension increases burn off rate increases.
27. Which of the statement is true about MAG welding?
It requires less skill than MMA welding.
28. Which of the statement is true about TIG welding?
In DC positive electrons flow to the tungsten from the work piece.
29. Which of the statement is true about hardness testing?
Brinell uses a Tungsten ball indenter.
30. Which of the statement is true about materials?
Aluminium has a proof stress value recorded.
31. Which of the statement is true about weld decay?
It is often referred to as sensitisation.
32. Which of the following has the greater risk of hydrogen cracking?
Using process 136 FCAW
33. What does the standard BS EN 14731 relate to?
Welding co-ordination tasks and responsibilities.
34. Which of the statement is true about UT?
It is useful on complex geometries.
35. Which of the statement is true about MAG welding?
100% CO2 cannot support Spray Transfer.
36. Which of the statement is true about TIG welding?
In DC negative,30% of the heat is in the tungsten.
37. Which of the statement is true about PWHT?
It has primary function of reducing stress by rearrangement.
38. Which of following MAG welding transfer modes has CTWD?
Spray transfer
39. Which of the statement is true about mechanical testing?
CTOD is for ECA.
40. What is the Chromium content of Duplex stainless steel?
22%
41. Which of the statement is true about weld decay?
Sensitivity can be reduced by using 347niobium.
42. Which of the statement is true about hydrogen cracking?
It happens when hardness exceeds 350 HV
43. What does standard BS EN ISO 9712 relate to?
Qualification of NDT personnel.
44. Which of the statement is true about Dye Penetrent Testing?
It can be used on any materials as long as it is non-porous.
45. Which of the following gases gives the greatest penetration in MAG welding?
CO2
46. Which of the statement is true about PWHT?
The temperature range for austenitic stainless steel is higher than the martensitic stainless steel, for the purpose of
desensitisation.
47. Which of the statement is true about TIG welding?
Aluminium is usually welded with zirconiated tungsten.
48. Which of the statement is true about CTOD?
Value >2 mm indicate a very tough behaviour.
49. Which of the statement is true about materials?
Nickel used in low temperature applications.
50. Which of the statement is true about MAG welding?
Dip transfer is all positional.
 Introduction to Metallurgy

1. If the constituent of an alloy are of different structures, what form would the alloy take?
Phase mixture
2. For binary alloy, what is the maximum number of phases that can generally exist together?
2
3. Which phase in the iron-carbon equilibrium diagram is face centred cubic?
Austenite
4. What composition of steel will result in the grain boundary precipitation of cementite (Fe3C) upon cooling from austenite?
Hyper eutectoid
5. What phase transforms to martensite upon rapid cooling?
Austenite
6. The Ar3 temperature is the temperature at which?
Austenite starts to transform to ferrite.
7. Which metallurgical process results in the formation of a fine grained structure in steel?
Recrystallisation
8. Hardness of metal can be increased by
Degreasing the grain size
9. At which temperature will austenite isothermally transform to coarse perlite in a 0.83% in carbon steel?
660® to 720® C
10. What is hardenability a measure of?
The rate at which austenite can be quenched to martensite without the formation of perlite.
11. The addition of manganese to steel will?
Increase both in the incubation period and the time necessary for transformations at specific temperature.
12. Which normalising temperature will give the finest grain structure for a steel with an Ac3 temperature of 840®C?
Normalising consists of heating the metal to a temperature about 50®C above the Ac3 temperature producing a refined grain
size. 840+50=890®C.
13. What is the effect of full annealing compared to normalising?
Larger the grain size
14. What is the effect of tempering after quenching?
Will increase toughness but decrease strength
15. The toughness and yield strength of a steel are increased by
Decreasing the grain size
16. What is the structure of alloying elements that tend to stabilise austenite?
Face entered cubic
17. Increasing the carbon contend of steel will?
Increase the hardness but decrease the toughness
18. What variations cause the change in structure across weld?
Cooling rate
19. How will the width of the HAZ tend to vary as the Heat Input of a weld is increased?
Width of the HAZ tends to increase as the Heat Input of the weld is increased.
20. If the Heat Input is cycled, the HAZ microstructure will tend to be?
Reined
21. Which element has the greatest effect upon the hardenability of mild steel?
Carbon
22. Which ingot mould design will minimise penetration of pipe in to the ingot?
Wide end up mould with hot top
23. Maximum segregation in steel ingots will occur?
Centre portions of the ingot
24. Fully Deoxidised steel is also known as?
Killed steel.
 Duties of Welding Inspector
1. Which of the following would be considered a primary role for senior welder?
Leading a team of welding inspectors.
2. QA is a part of Quality Management that is focused on?
Providing confidence that quality requirements will be fulfilled.
3. What is the purpose of QC manual?
Spells out in detail how different departments and operations are organised and controlled.
4. Which of the following statements best defines the term specification?
Documents that state requirements relating to activities or products.
5. What could be defined as a “document recommends practices or procedures for the design, manufacture,
installation, maintenance, utilisation of equipments , structures or products?
Code of practice.
6. BS EN ISO 9606 refers to standard for?
Welder approval
7. Which of these standards to refer to qualification of welding procedure?
ASME sec IX, BS EN ISO 15614
8. Which of the following skills would a senior inspector will require?
Basic understanding of metallurgy, knowledge of QA & QC and the ability to assess NDT reports etc.
9. Senior welding inspectors should be able to?
Ability to Interpret radiographs.
10. Which of the following statements defines Quality?
Degree to which a set of inherent characteristics fulfils explicit and implicit requirements.

Welding procedures
1. What is the main reason for qualifying welding procedures?
Show that the welded joints have the required quality and mechanical properties.
2. Which standard outlines the specification of and qualification of welding procedures for metallic materials?
EN ISO 15614
3. Why do welding inspectors need to understand the welding procedures specification?
They will need to refer to them when they are checking welders are working in accordance with the specified
requirements.
4. Drag and drop these steps into the order that they are performed during a welding procedure?
PWPS, WPQR, WPS, WELDER APRROVAL
5. What does WPQR stands for?
Welding procedure qualification record.
6. Which standards specify the requirements for welder qualifications for the fusion welding of steels?
ES ISO 9606
7. Which of the following are examples of WPS essential variables?
Welding process, welding consumables, material type and polarity.
8. According to European standards, how often do welder qualification certificates need to be validated?
6 months
9. Which NDT method is always required for a welding procedure qualification of test welding?
Visual Inspection.
10. Would a welder have to re-qualify if the original qualification is process 135, but they are now required to weld
with process 136?
Requalification is required due to process is essential variable.

Weld ability of steels

1. Which of the following statements are true?
Weld ability means the ability of metals or alloy to be welded and poor weld ability normally results in the
occurrence of cracking.
2. What is the major alloying element in steel?
Carbon, strengthening element with a major influence on HAZ hardness.
3. Why is manganese added to steel?
To improve strength and toughness.
4. Which one of the following is added to steel to give resistance to creep at elevated service temperatures?
Molybdenum 0.5 % to 1.0 %
5. Which of the following increases the maximum hardness in the HAZ of steel?
Higher the CEV higher the hardness and susceptibility to brittleness and lower the weld ability.
6. Carbon equivalent values are used to determine how to avoid the risk of ?
Hydrogen cracking
7. How does increased preheat help prevent to hydrogen crack?
Increases the diffusion of hydrogen during welding.
8. Drag welding process n to the correct order. Based on their potential lowest hydrogen content with regards to
100grms of deposited weld metal?
TIG, MMA, SAW, FCAW
9. Why does a low heat input increases the risk of hydrogen cracking?
Fast cooling. (HAZ hardness is a good indicator of susceptibility to H2 cracking).
10. What could a crack running along centre line of a weld bead be caused by?
Deep, narrow weld bead. (Solidification the bonding between the grains may too poor to maintain cohesion and a
crack may result.
11. Which of the following is most likely to lead to solidification cracking in steel?
Sulphur in the parent material may dilute in the weld metal to form iron sulphides, which are low strength and low
melting point compounds.
12. What is solidification cracking also known as?
Hot cracking
13. Why does the manganese added to the filler to avoid the solidification cracking?
MnS increases the cohesion and strength between the grains.
14. Which of the following is high dilution process and most likely to give a weld profile that deep and narrow?
SAW (MIG/MAG spray transfer also give weld bead Deep and narrow)
15. What is the pattern of lamellar tearing?
Stepped pattern
16. What causes a parent metals poor thickness ductility?
Solid inclusions can link up and crack under through-thickness stress.
17. Which susceptible microstructure is most likely to result in weld decay?
Sensitised grain boundaries can lead to lowering of metals resistance to corrosion attack. allowing rusting to occur.
18. Which of the following would reduce the risk of weld decay?
Stabilized grade stainless steels contain titanium or niobium which forms carbides preferentially to Cr.

NDT
1. The tendency of a liquid Penetrent to enter a discontinuity is primarily due to
Capillary forces
2. What is the primary function of the couplant used in pulse echo contact ultrasonic testing?
To reduce reflection at the sound entry surface and improve transmission in to the test material.
3. Which of the following is an advantage of Dye Penetrent flaw detection?
Used on non-ferromagnetic materials.
4. Which is inspecting an austenitic stainless steel butt weld for surface and subsurface defects, which non
destructive testing would you employ?
DPI and RT
5. In the RT of butt welds in pipe, what are ‘source inside film outside and film inside source outside both examples
of?
SWSI
6. What is the process by which a Penetrent is drawn out of discontinuities by the developer?
Capillary action.
 7. If detected by RT what would a lack of side wall fusion appear as ?
Very thin continuous or intermittent. Straight dark line running parallel with the edge of the weld cap.
8. What is DPI development time influenced by?
Type of Penetrent used , the type of Developer used, the temperature of the material being tested.
9. What is the correct term for the image that forms on RT film during exposure to radiation.
Latent image
10. If detected by RT, what could undercut appear as?
Dark line of variable width, continuous or intermittent, Between the weld and parent material, following the
contour of the edge of the weld cap or root.
11. Which of the following is a disadvantage of DPT flaw detection?
Surface breaking continuities.
12. What is the phenomenon that produces both relevant and non relevant indications in MPI?
Magnetic flux leakage
13. RT is the reliable method for the detection of which defects?
Volumetric flaws
14. Magnetic lines of force are oriented in what direction relative to the magnetising current?
Right angles to the magnetising current.
15. What is a dual type Penetrent?
Can be used with either visible or UV-A light.

Destructive Testing
1. Which bend test would be used on a 14mm single vee carbon steel butt weld?
Side bend tests are used on butt welds >12mm
2. With a tensile test the strength of what is being determine?
Joint
3. What is the Charpy test used to measure?
Notch Toughness
4. Which of the following is the quantitative test?
Tensile test, hardness test, Charpy impact test
5. What is the purpose of bend test?
Soundness of the weld zone, showing any internal defects.
6. What is STRA test used to measure?
Through thickness Ductility of the parent metal.
7. Which of the following is the qualitative test?
Bend test, macro/Micro, fillet fracture test, Nick Break test
8. What can side bend test to be used to find?
To find Lack of fusion defects.
9. Which tensile test can be used for assessing the risk of lamellar tearing?
STRA
10. How is the elongation value of tensile test specimen calculated?
Dividing the change length by the original length and multiplying by 100
11. What is the plastic region of tensile test?
The point at which the sample is permanently deformed.
12. What is an all weld tensile test?
Specimens for all weld tensile test are weld metal only.
13. Which statement is correct concerning a Charpy impact test?
Used to determine Material’s Toughness.
14. Which of the following typical bend angle for the bend test?
180®
15. In a tensile test, which of the following represents the maximum load before failure?
Rm
16. Which destructive test clearly shows the lack of root fusion?
Fillet fracture test.
 17. Which destructive test would give information regarding number of weld run deposited?
Macroscopic test
18. The diameter of the former of the bend test is normally?
4 times of the material thickness
19. In tensile test which of the following is represents yield strength?
Re- yield strength, ReH- upper yield strength, ReL – lower yield strength)

Welding process
1. Which power source characteristic is required for MIG/MAG welding?
Flat output characteristic
2. Which polarity welding current would be used to weld aluminium using TIG process?
AC
3. In arc welding process penetration most affected by?
Amperage
4. Why is constant voltage power source usually used in MIG/MAG welding?
It’s generate self regulating arc
5. How oxide removal is is primarily obtained in TIG welding?
Using an AC current
6. In MMA welding, which type of flux covering gives the deepest penetration?
Cellulosic
7. In submerge arc welding; what can increase the bead width?
Increase the voltage
8. Which power characteristic is required for MMA welding?
Constant current
9. In TIG welding, what can reduce start / stop defects?
Slop up / down devices
10. In TIG welding, which shielding gas can be used for the widest range of material?
Argon
11. In order to flatten the profile of a convex weld bead during deposition of a SAW, what would slightly increase?
Slightly increase the ARC voltage
12. In MIG/MAG welding, what is the wire feed speed is directionally proportional to?
Current
13. When TIG welding why Helium often added to argon?
In order to Increase the penetration.
14. In MAG welding, what would be the effect of the contact tip to work distance CTWD extending?
Current will decrease
15. What is the power source characteristic used for the TIG welding process?
Constant current
16. When using the SAW process with tandem wire, how is arc blow often reduced?
DC leading arc, and AC trailing
17. Using maximum inductance with the MAG process has which of the following effects?
Reduced spatter
18. Which of the following typical current and voltage for the Dip transfer?
24V and 200A
19. Which of the features apply to spray transfer?
High deposition rate
20. In MMA welding which polarity would give the highest level of penetration?
DC positive.

Residual Stress and Distortion

1. Balanced welding techniques are
To reduce distortion
2. Which of the following would be expected to produce least distortion in a 1.5 mm thick straight butt weld?
TIG welding
3. When welding thin plate, distortion can be minimised by?
Sequential welding
4. Why stresses are undesirable?
Because they affect dimensional stability
5. Which of the following would give the least stress in a welded joint?
Fast travel and narrower weld beads
6. Which of the following will increase stresses?
Deposited weld metal thickness increases
7. Which of the following material properties has the greatest influence on welding distortion?
Co-efficient of thermal expansion
8. When referring to the austenitic stainless steel, which of the following statements would be correct?
Low efficient of thermal conductivity
9. Which of the following materials will have highest residual stress, if the weld was a 10 mm single V thick butt
weld,1m in length?
Carbon Manganese steel
10. Which of the following materials will distort the most, if the weld was 10mm thick single V butt weld, 1m in length?
Austenitic stainless steel because low thermal co-efficient of thermal conductivity

Fracture Assessment
1. Which one of the failure is associated with Temperature change?
Brittle
2. What would the surface of a Ductile fracture normally shows?
45® Shear Lips
3. What type of failure are chevron marks associated with?
Pointing back to the Initiation Source
4. What type of failure is associated with overloading?
Ductile
5. What would the surface of a fatigue failure normally show?
Beach marks
6. Which of the statement is true about fatigue failure?
Can occur at stresses well below the yield stress of the material