Check course schedule Is it for me? The online material covers approximately 3 days learning. As a direct result of training with TWI, I have seen an extraordinary change in my career and personal life Fatchur, Indonesia Inspecting the inside of a pipe for defects Measuring the weld reinforcement on a pipe Measuring the length of a defect on a pipe Previous image Next image What will I learn? This course will teach you the duties and responsibilities of a welding inspector including fusion welding processes, typical weld defects, types of steel including carbon-manganese, low alloy and stainless steels , the hardening of steels, weldability, heat treatment, and parent metal defects.

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When manual metal arc welding is being carried out on an open construction site, which group of welders are the most likely to require continuous monitoring? You notice manual metal arc electrodes, stripped 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 d The wire is too short 5. 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 d Day temperature 6. The steel composition in a structural contract is changed form 0.

Might this influence the incidence of: a Porosity b Cracking in the weld area c Undercut for fillet welds d Lack of root fusion defects 7. One of the following alloys is non-magnetic. This is to: a Prevent oxidation b Prevent under bead cracking c Prevent porosity d Control the penetration bead shape 9.

Pre-heating a carbon steel manual metal arc welding is carried out to minimize the risk of: a Scattered porosity b Worm hole porosity c Parent metal cracking d Lack of penetration In UK practice, BS part 2 specifies that the drawing dimension quoted for a fillet weld is the: a Leg length b Actual throat thickness c Weld length For open site manual metal arc welding the following equipment is available. Which would you choose for safe working?

If Submerged arc welding is to be used to make butt welds, which would you be most critical of? During CO2 welding, the arc length is most likely to be affected by: a The wire diameter b The current return connection c The gas flow rate d The torch to work angle Preheating for arc welding applies to: a Assembly welding only Page 2 of 43 b Assembly and tack welding c Joints over 25mm thick only d Cruciform welds only 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 welder qualification test is to verify: a Skill of the welder b The quality of the materials c The non-destructive test procedures d The manufacturing method 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 Lamellar tearing has occurred in a steel fabrication. Before welding could it have been found by: a X-ray examination b Dye penetrant c Ultrasonic inspection d It would not have been found by any inspection method You are to oversee the arc welding of some machined fittings and find they are cadmium plated. Would you: a Permit it to proceed b Permit it to proceed with fume extraction c Stop the operation at once d Advise the welder to drink milk and proceed The unit of Joules would be used to measure: Page 3 of 43 a Tensile strength b Impact energy c Hardness d Electrical resistance Submerged arc welding is a process that generally gives: a Slag free welds b Low penetration c Low dilution d High heat input Which of the following does not require baking or drying: a E b E c Sub are flux with Basicity Index of 2 d Sub are flux with Basicity Index of 3 A welder and procedure re-qualification would be required: a When the run out date of the procedure has been reached b Every Year c When changing from day to night shift work d When there is a change in an essential variable Tensile strength can be increased in steel by: a Annealing b Galvanising c Addition of carbon d Casting Which of the following always occurs in the parent material: a Hydrogen cracks b Laps and laminations c Center line cracks d Porosity To prevent the hardening and cracking of High Carbon Steel plate when flame cutting it is advisable to: a Pre-heat the plate b Soak the plate in oil c Cool the plate quickly after cutting d Increase the cutting Oxygen pressure Re-crystallization during annealing is used to make steel: a Softer Page 4 of 43 b Harder c Tougher d Stronger You should always refer to a higher authority for guidance when: a Cracks appear during welding b The welder will not follow your instructions c Instructions are missing in the specification or contract documents d All of the above Fatigue testing is used to test welds: a Under cyclic loading b Under creep stress loading c Under impact loading d Under static loading In BS and BSEn the first digits of the electrode classification indicate: a Tensile and yield strength b Toughness c Electrode coating d Electrode efficiency Cellulosic coatings are generally used because of: a Their low hydrogen content b Their high penetration characteristic c Their high strength weld deposit d Their high weld toughness values When welds have a depth to width ration of higher than it is possible that: a Centerline cracks may appear b The fusion boundary will be outside the HAZ c The HAZ will be too narrow d The weld will be non magnetic On which of the following would you not use MPI inspection?

Increasing the arc energy input of a welded joint will: a Increase the strength of the joint b Increase the toughness of the joint c Increase the grain size of the weld and HAZ d Decrease the width of the HAZ In Sub Arc Welding, excessive flux melting will result from: a Increasing the arc voltage b Decreasing the arc voltage c Increasing the travel speed d Increasing the wire feed speed To BS part 2, which of the following is true for a welding symbol: a This or arrow side of the joint goes on top of the reference line b This or arrow side of the joint goes below the reference line c This or arrow side of the joint goes in the middle of the reference line d All of the above Internal lack of fusion defects can be normally found by using: a Penetrant testing b Impact tests c Side bend test d Hardness test Which of the following steel structures has the highest hardness: a Martensite b Austenitic c Ferritic d All have the same hardness Silicon is added to electrode coating as: a A slipping agent b A slag former c A de-oxidant d A colouring agent 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 Which of the following is an inspection point in Sub Arc Welding?

Why is Hot Pass so called? Which of the following is not inert gas? Why is a welding arc shielded? Which welding process is considered to be the most versatile?

The HAZ associated with a weld is: a The melted portion of the parent plate b The area immediately adjacent to the weld which has undergone a micro structural change c The weld area plus the parent plate which has undergone a micro structural change d The are in the weld region with the lowest tensile strength A crack in a weld zone: a Is repairable b Always results in a cut out and complete re-weld c Is acceptable up to 2mm in length d May be repaired or cut out depending on specification requirements If the amperage is too low during the welding of a root bead, the possible result would be: a Lack of penetration b Lack of fusion c The freezing of the electrode d All of the above Page 8 of 43 Pre-heating prior to welding: a Must always be carried out b Need not be carried out if post heat treatment is to follow welding c Is always carried out using gas flames d All of the above e None of the above Cold lap in another term for: a Lack of fusion b Low amperage c Undercut d Hydrogen cracking When a medium to high carbon steel is quenched: a It becomes malleable b Its hardness increases c It becomes ductile d The plasticity is increased One of the advantages of a multi-pass MMA weld is that it generally produces a: a High tensile strength b High degree of ductility c Coarse grain structure d Fine grain structure The extent of the changes in microstructure will depend on the following: Page 9 of 43 a Material composition b Heat input c The rate of cooling d All of the above A code of practice for visual inspection should cover the following: a Before, During and After welding activities b Before welding activities only c After welding activities only d None of the above Incomplete root fusion would certainly be caused by: a Linear misalignment b Incorrect tilt angle c Differing root face widths d All of the above This is most likely caused by: a Poor consumable choice b Welding position c Excessive travel speed d None of the above Undercut is caused by: a Excessive amps b Excessive volts c Excessive travel speed d All of the above Undercut is normally assessed by: a Its depth b Its length c Its blending d All of the above An essential variable may: a Change the properties of the weld b Influence the visual acceptability c Require re-approval of the weld procedure d All of the above MIG welding tends to be susceptible to lack of fusion problems.

This is because of: a Poor maintenance of equipment b Incorrect settings c Poor inter run cleaning d All of the above MMA electrode can be grouped into three main types. Cracks in welds may be due to: a Solidification problems b Hydrogen problems c Excessive stresses d All of the above Welding a single V butt with laminations showing on the side wall may give rise to: a Lamellar tearing b Solidification cracking c Martensite d Undercut With reference to a root penetration bead, you could certainly assess: a Root fusion and penetration Page 12 of 43 b Root concavity c Burn through d All of the above A fatigue failure is characteristic by the appearance of the fracture surface.

This is because: a It may reduce the thickness dimension of a component b It may cause liquation cracks c It may cause hard zones d All of the above Overlap in welds could be influenced by: a Poor welding technique b Welding process c Welding position d All of the above Flame cut preparation may, during welding, increase the likelihood of: a Cracking b Misalignment problems c Inclusions d All of the above Macroscopic examination requires any specimen to be inspected: a Once after welding b Twice — once before and once after etching c Using a microscope d None of the above A code of practice is: a A standard for workmanship only b A set of rules for manufacturing a specific product c Levels of acceptability of a weldment d None of the above Page 13 of 43 A metallurgical problem most associated with Submerged Arc welding is: a Hydrogen cracking in the HAZ b Solidification cracking in the weld metal c Hydrogen cracking in the weld metal d Lamellar tearing in the weld metal Oxy pressure and nozzle size would influence what in flame cutting: a The temperature required for cut initiation b The ability to cut Stainless steel c The depth of cut obtainable d None of the above Which of the following processes joints metals plastically: a Friction welding b Resistance welding c Plasma welding d All of the above Which electrode classification would be relevant to AWS A5.

The type of SAW flux is more resistant to moisture absorption: a Fused b Agglomerated c Basic d All of the above the same resistance A large grain structure in steels said to produce: a Low ductility values b Low fracture toughness values c High fracture toughness values d High tensile strength The likelihood of brittle fracture in steels will increase with: a A large grain formation b A reduction of in-service temperature to sub zero levels c Ferritic rather than austenitic steels d All of the above Repair welding is often more difficult than production due to: a The material being ingrained with in-service contaminates b Restricted access within the repair area c The possible position of the weld repair d Any of the above EN standard would refer to which of the following: a Welder approval testing b Welding equipment c Welding procedure approval Page 15 of 43 d Consumables for Submerged arc welding Porosity is caused by: a Entrapped slag in the solidifying weld b Entrapped gas in the solidifying weld c Entrapped metallic inclusions in the solidifying weld d None of the above 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: a A root bend test b A side bend test c A face bend test d None of the above Ultrasonic testing is of advantage in detecting which of the following weld imperfection over other NDT method: a Lack of side wall fusion b Surface undercut c Incompletely filled groove d Overlap The process of tempering is often carried out to regain toughness after which of the following processes: a Annealing b Normalising c Hardening d Stress relieving The presence of iron sulphide in the weld metal is most likely to produce which of the following upon contraction of the weld: a Solidification cracking b Hydrogen cracking c Intergranular corrosion d Stress corrosion cracking Hot shortness is a term used to indicate: a Lamellar tearing b Solidification cracking c Hydrogen cracking d None of the above The use of cobalt as an isotope would generally be used on: a Thin material b Tee joints c Plate thickness greater than 25mm d None of the above The correct terminology in the preceding question 7 is: a - b - c - d - Page 17 of 43 The important point of high temperature steels is that: a They can withstand creep failure b They may suffer re-heat cracking problems c They may suffer loss of toughness d All of the above An austenitic stainless steel may suffer: a Weld decay b Sensitisation c Solidification cracking d All of the above Carbon equivalent values are useful to determine: a Weldability aspects b Crack sensitivity aspects c Typical mechanical properties d All of the above The most serious defect types are: a Planar b Cracks c Lack of fusion d All of the above Which of the following discontinuities could be as a primary processing discontinuity often found in cast material?





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