STANDARD QUESTIONS WITH ACCEPTABLE ANSWERS FOR DEMONSTRATION 4. How can you obtain and relay work related information/messages to your team whenever you are out of the workplace/office? ANSWER: Use an email or cell phone/telephone 2. How can you perform the activity with minimal errors? ANSWER: Follow the instruction accordingly 3. How do you help achieve job targets of the group? ANSWER: ° Help team members © Participate/Cooperate in every work group activity 2 Perform job duties/responsibilities 4, Why do you need specification details/instructions when asked to do a task? ANSWER: © To ensure that the processes/procedures to apply are in accordance with the requirements 2 To avoid unwanted results * To maintain normal course of operation s __ Toavoid damages & company loss 5. How can eliminate too much waste/defects during the operation? ANSWER: Immediately report non-conformance in the process 6. High wind velocity can cause porosities in weld, what must be done to prevent this from happening? ANSWER: If welding in windy area cannot be avoided, wind shield or barrier should be installed 7. How will you prevent an arc blow? ANSWER: 2° Use transformer type welding machine ° _Change the position of the return or work cable 8. What are the welding parameters that must be considered to produce quality weld? ANSWER: * Current setting ® Length of arc ° Angle of electrode * Manipulation of electrode (weave or stringer) 2° Speed of travel7 | 9, What ard the purposes of electrode coating or nux+ ANSWER: s To shield from atmospheric contamination ¢ _ Toclean the weld base metal and electrode during welding ° To provide additional alloying elements for weld deposit 2 Toincrease ate stability __Toincrease deposition rate | 40. What is the ideal length of arc? What is the effect to long arc? ANSWER: © ArG length should be approximately equal the diameter of the core of the electrode. | . Excessively long arc increases voltage and produce spatter, low deposition | “rate, undercuts and maybe porosity | 44. Whatis the effect on the weld if the electrode is held too closely to the material | being welded? | ANSWER: Holding the electrode too closely decreases welding voltage, creating an erratic arc that may extinguish itself or cause the rod fo freeze, as weil as | produces a weld bead with a high crown. 42. | Whatare the types of welding electrodes used in shielded metal arc welding? ANSWER: Cellulosic iron powder Rutile Basic | | 43. How would you prevent welding-related injuries? ANSWER: . Use appropriate welding PPEs ° Proper handling of equipment, tools and materials ° Awareness to safety practices 44. How would you avoid electric shock during welding? ANSWER: Ground all electrical equipment and the workpiece Use the recommended cable size Make sure all electrical connections are tight, clean and dry Keep work area, equipment and clothing dry at all times Keep cables and connectors in good condition at all times Wear insulated gloves when adjusting equipment Follow safety standardsr 45. What should be done to prevent warpage or distortion? ANSWER: © Donot overweld ° Use intermittent welding . a ° Use as few weld passes as possible ° Use appropriate welding sequence . Consider distortion allowances ° Use clamps, jigs and fixtures to lock parts in position } Use clamps, jigs and fh | 46. | What causes warpage or distortion? ANSWER: ° Wrong joint preparation 2° Incorrect welding techniques 2 Use of high amperage 2 Improper bead size/profile Wrong choice of diameter electrodes 17. Whatis the cause of poor penetration and incomplete fusion? | ANSWER: | = Insufficient root gap | 2 Too low welding current 2 __ Incorrect electrode angle | 18. Whyis stress-relieving should be done? | ANSWER: Stress-relieving should be done in order to release stresses in ihe welded structure cause by wrong welding procedure and techniques. |18. Why is back step welding technique being applied? | ANSWER: Back step welding is performed to minimize or prevent distortion and is accomplished by welding in segments. | 20. — How would you prevent the occurrence of slag inclusion? ANSWER: 2 Clean the base metal (remove paint, oil, etc.) 2 Remove slag before re-starting welding 21. What are the advantages of SMAW process? ANSWER: 2 Equipment used is simple, inexpensive and portable ° Electrode provides and regulates own flux * Lower sensitivity to wind and drafts than gas shielded welding process All position capability| 22. What at the disadvantages or limitations of SMAW process? ANSWER: ° It fequires deslagging after each weld e elding must be stopped after each electrode ° It forms harmful fumes during welding 23. Welds inkhick carbon steel materials has the tendency to crack, Why? ANSWER: Cracks on weld in thick carbon steel materials are caused by the rapid cooling of the weld 24. What factors must be considered in the selection of electrodes? ANSWER: 2 Be sure electrode will operate on the available welding machine being used . Electrode must match base metal properties 2 Electrode must be of appropriate size for the job 25. What are the types of welding machines that can be used for Shielded Metal Arc Welding process? Transformer type Rectifier type Transformer — rectifier type Generator type Inverter type aaeno\n SMAW, when the polarity is set to the DCEN, it is otherwise known as: A Reverse polarity B. AC Balance Polarity c Straight Polarity D. Direct Current European Norm The welding symbol shown represents what type of weld? Single Bevel weld V-cut Groove weld 7 ara Single-vee weld \V-Butt joint oomP Which of the following will represent a T-joint when viewed from the top? cI “T A joint between two members located approximately at right angles to each other in the form of an L A. Edge joint B. Comer joint C. Tee joint D. Lap joint When two members of a joint is aligned approximately in the same plane, it is called A. Buttweld B, —_Butting member C, — Buttjoint D. —_Buttering412. 413. 15. What electrode requires drying before using? A. Low hydrogen B. Cellulosic Cc. Rutile D. tron powder Which plate thickness requires edge preparation for welding? A s3mm B. >6mm c. +6 mm D. 23mm Which type of welding machine is not suitable for E-6010 electrodes? A. Rectifier B. Diesel driven C. Transformer (AC) D. _ Inverter Type Which electrode coating is best used to weld low alloy steel materials Cellulose Low Hydrogen Rutile Acid gpoOmP When a piece of mild steel is heated by the application of an electric arc, and then cooled rapidly by quenching in water , the material is expected to: A. Crack B. expands its size C. elongate D. no significant changeAT. 18. 20. Which of the following test is used to checked the external discontinuities of a weldment? A Radiographic Test BL Ultrasonic Test Cc. Bend Test D. Visual Test Which electrode is required to be stored in th eir original factory sealed container or an acceptable storage oven. AS E-6011 B. E-7018 Cc. E-7024 D. All of the above The designation” E-7028"denotes that the electrode could be used for: All welding position Overhead welding position Vertical welding position Flat and Horizontal welding position GORPr Which electrode flux covering is generally used when deep penetration is a requirement? Cellulose Low Hydrogen Rutile Acid poaP A technique in welding used normally for vertical joints in which the electrode sweeps back and forth in a semi-circular motion. Wash welding Layering Weaving A. B. Oy D. BothA&CElectrode designation E6010 is specifically designed for use on A. direct current electrode negative polarity only B. AC-DC Cc direct current electrode positive polarity onl D. AC only 27. — Ali of the following are welding electrodes used for SMAW process EXCEPT: A ER70S B. €7010-P Cc. £7018-B2L Db. E6013 « 28. What factors were determined that have NOT caused the presence of porosity ? Welder use excessively long arc when using E 7018 electrode Magnetic arc blow CORP Moisture from electrode, base metal and surroundings Thick base material 29. Agroove melted into the base metal and left unfilled by weld metal is known as Underfill Concavity Crater Undercut gORP 30. When metal particles where expelled during welding and that do not form as part of the weld, what was likely being detected during visual check A. Are strike B. — Spatters C. Melt thru D. Slag31. 32. 33. 35. To re i duce the effect of Magnetic arc blow which alternative can be used. Increase welding current A. B. Use generator type welding machine Cc Change welding machine from DC to AC D. Use rectifier type welding machine What does a welder qualification test requirement determine? Welder’s ability calibrate welding equipment Ability to understand and perform joint design A. Ability of welder to deposit sound weld metal as per WPS B. Cc. D. none of the above When electrode coating absorbs moisture, it is most likely that the weld will have A. excess penetration B. _ porosities C. shallow penetration D. too much undercut Arc strike occurs due to high current exposed electrode spatters improper start pORP When a welder passes a 5G pipe qualification, which of the following is covered in his/her qualification A, _ 5F plate and 4G pipe position B. _1F plate up to 6GR pipe position C. 2G pipe and 5G pipe position D. —Alllpositions37. 38. 39. 40. 7 ge or explosion during oxy- A Backflow Arrestor B. Check Valve Cc. Non return valve D. relief valve The main objective of welder’s performance qualification test is to: foretell how a welder will perform in the production line build complete reliance of the assessor in his performance test result. A assess whether he has the minimum skill level to produce sound welds B. Cc. D. —_ understand joint design A repair work for a discontinuity like Undercut may be prevented by which of the following Increasing current and voltage setting Maintaining appropriate arc length Decreasing stop time (dwell time) on weaved beads Grinding the sharp edges of the weld toes’ cOnP Which of the following is NOT considered arc hazard? A radiation B. fall Cc. electric shock D. fumes and gases For a 3 mm dia, Electrode for SMAW, what is the recommended shade for dark glass? A #6 B. #8 Cc. #10 Db. #12