18 For fillet welds it is normal practice in the UK and USA to measure:

a Throat thickness. b Leg lengths. c Penetration depths. d Both a and c.

22 The main cause of undercut is:

a Excessive amps.
b Excessive OCV.
c Excessive travel speed.
d Current too low.

38 Which type of power source characteristic is normally used for manual welding?
a Constant voltage. b Flat characteristic. c Constant current. d A motor generator

39 In MMA welding penetration is principally controlled by:

a Arc voltage. b Welding speed.
c Ferro-silicon in the electrode coating. d Current.

45 The term low hydrogen electrode is often used for certain electrodes. What type of covering will they
have?
a Cellulosic. b Rutile. c Acid. d Basic.

46 A hydrogen controlled MMA electrode can always be recognised by the:

a EN code letter (or AWS code number). b Electrode length.
c Trade name. d Colour of the covering.

APP 2:

8 Non planar defects:

a Are always repaired.
b Their existence will result in the removal of the entire weld. c They are not usually as significant as
planar defects. d They can only be detected using radiography.

19 When conducting a visual inspection on a butt weld you notice an excessive chevron shaped cap
ripple. This may indicate which of the following?
a Incorrect electrode. b Excessive travel speed.
c Incorrect pre-heat applied.
d That the welding has been carried out in the PF welding position

27 MMA welding process:

a Uses a constant voltage. b Uses a flat characteristic. c Uses a drooping characteristic. d Uses both a
and.

28 Which of the following electrodes and current types may be used for the TIG

welding of nickel and its alloys?

a Cerium electrode, DC –ve. b Zirconium electrode, AC. c Thorium electrode, DC +ve. d All of the above
may be used.

29 Travel speed:

a If too fast may cause low toughness, slag inclusions and cap undercut.

b If too fast may cause high hardness, slag inclusions and a narrow thin weld bead.

c If too slow may cause high hardness, excessive deposition and cold laps.

d None of the above.

46 Brittle fractures:

a The susceptibility in steels will increase with the formation of a fine grain structure.

b The susceptibility in steels will increase with a reduction in the in-service temperature to sub-zero
conditions.

c The susceptibility in steels will increase with a slow cooling rate.

d All of the above.

41 When calibrating a mechanised MAG welding plant, which of the following applies?

(WFS = Wire feed speed)

a Check – WFS, current, volts and wire diameter.

b Check – WFS, joint set-up and gas flow rate.

c Check – Gas flow rate, stick out length, WFS and current.

d All of the above.

40 Which of the following best describes a semi-automatic welding process?

a The welder is responsible for maintaining the arc gap and travel speed.

b The welder is responsible for travel speed only arc gap is kept constant by the welding plant.

c Both travel speed and arc gap is controlled by the welding plant.

d All of the above.

36 Which of the following statements is false?

a In the MMA welding process AC current produces the deepest penetration.

b DC electrode positive is used for the MAG welding of steel plate.

c In the MAG welding process the wire feed speed remains constant during the welding operation.

d All of the above.

47 Which of the following are considerations for the selection of a preheat temperature?

a Carbon equivalent, joint design, welding process and plate material quality.

b All Joints over 25mm thick, hydrogen levels, welding process, carbon equivalent.

c Arc energy, material thickness, hydrogen scale and carbon equivalent.

d All of the above are considerations for the selection of a preheat temperature.

49 Welds made with high heat inputs on C/Mn steels, show a reduction in one of the

following properties?

a Ductility. b Toughness. c Elongation. d Penetration.

50 Which of the following elements, which may be added to steel, has the greatest effect on creep strength?

a Tungsten. b Manganese. c Carbon. d Molybdenum.

11 Which type of submerged arc welding flux is susceptible to moisture pick-up?

a Neutral. b Agglomerated. c Fused. d All about the same

13 A STRA test is used to measure the:

a Tensile strength of the welded joint.

b Level of residual stress in butt joints.

c Fracture toughness of the HAZ.

d Through-thickness ductility of a steel plate (the Z direction)

14 The risk of hydrogen cracking is greater when MMA welding:

a C-Mn steels.

b Austenitic stainless steel.

c Low alloy steels for elevated temperature service.

d Low carbon steels for cryogenical service.

15 The property of a material which has the greatest influence on welding distortion is its:

a Yield strength.

b Coefficient of thermal expansion.

c Elastic modulus.

d Coefficient of thermal conductivity.

16 Which of the following is a suitable shielding gas for FCAW of stainless steels?

a 100% argon.

b 70% argon + 30%He.

c Argon + 5% hydrogen.

d Argon + 20% CO2.

17 The presence of iron sulphides in a weld bead may cause

a Solidification cracking.

b Hydrogen cracking.

c Lamellar tearing.

d Weld decay.

21 Which of the following is associated with SAW more often than it is with MMA welds?

a Hydrogen cracking in the HAZ.

b Solidification cracking in the weld metal.

c Reheat cracking during PWHT.

d Lamellar tearing.
27 For GMAW the burn-off rate of the wire is directly related to:

a Stick out length.

b Wire feed speed.

c Arc voltage.

d Travel s28 When MMA welding a 60mm wall nozzle to a 100mm wall vessel shell, preheat

temperature should be checked:

a Before welding starts/re-starts.

b On the shell and nozzle.

c At points at least 75mm from the joint edge.

d All of the above. peed.

30 To improve resistance to service failure caused by cyclic loading, it is good practice to:

a Use low heat input welding.

b Use steel with a low CEV.

c Ensure there are no features that give high stress concentration.

d PWHT the fabrication.

31 The use of low carbon austenitic stainless steels and stabiliser stainless steels will minimise the risk of:

a HAZ cracking.

b Weld decay.

c Weld metal cracking.

d Distortion

32 Which type of SAW flux is susceptible to breaking down into fine particles during

circulation?

a Fused.

b Neutral.

c Alloyed.

d Agglomerated

33 The maximum hardness in the HAZ of a steel will increase if:

a Heat input is increased.

b CEV is increased.

c Joint thickness is decreased.

d Basic electrodes are used.

35 A C-Mn steel is being welded by MMA and the electrode run-out lengths that have

been used are much shorter than specified by the WPS. This deviation may give:

a Increased risk of hydrogen cracking.

b Increased risk of solidification cracking.

c Lower values of HAZ toughness.

d Higher values of HAZ hardness.

38 When welding thin plate distortion can be minimised by:

a Welding from both sides.

b Using U preparations rather than V types.

c Using strongbacks.

d Using back-step welding.

42 BS EN 288 and BS EN ISO 15614 are specifications for:

a Welder approval testing.

b Welding equipment calibration.

c Welding procedure approval.

d Consumables for submerged arc welding

47 In friction welding, the metal at the interface when the joining occurs is described as being in the:

a Liquid state.

b Intercritical state.

c Plastic state.

d Elastic state.