CSWIP 3.1 Part 5

A welding inspector is responsible for ensuring the quality and integrity of welds. This includes checking the condition of the parent material and consumables, as well as verifying calibration certificates to ensure accurate measurements. However, measuring residual stress is not typically within the scope of a welding inspector's duties. Residual stress is a complex measurement that requires specialized equipment and expertise, often performed by materials engineers or metallurgists.

In this situation, since the specification does not provide any requirements for visual inspection, it is best to seek advice from higher authority. This is because they may have additional information or guidelines that can help determine the appropriate approach for visual inspection. Seeking advice from higher authority ensures that the inspection is carried out correctly and in accordance with any relevant guidelines or standards.

The term given for the area of a welded joint outside the weld metal that has undergone microstructural changes is the heat affected zone. This zone is affected by the heat from the welding process, causing changes in its microstructure and potentially altering its mechanical properties. The other options, such as the weld zone and fusion zone, do not specifically refer to the area outside the weld metal that has undergone microstructural changes. Therefore, the correct answer is heat affected zone.

In welding, different positions refer to the orientation of the welding joint. The PA position, also known as the flat position, is where the welding is done horizontally on a flat surface. This position allows for better control of the welding process, resulting in a higher deposition of weld metal. In contrast, the other positions (PG, PE, and PC) involve welding on vertical or overhead surfaces, which can be more challenging and may result in less weld metal being deposited. Therefore, under most conditions, the PA position will deposit the most weld metal.

When measuring the welding parameters with the MMA welding process for the purpose of approving a welding procedure, it is important for the welding inspector to measure the voltage as close to the welding arc as possible. This is because the voltage at the welding arc directly affects the quality and characteristics of the weld. By measuring the voltage at this point, the inspector can ensure that the welding parameters are within the specified range and that the welding procedure is being carried out correctly. Measuring the voltage anywhere along the welding cable or from the voltmeter on the welding plant may not provide an accurate representation of the voltage at the welding arc. Similarly, measuring the voltage as near to the welding terminals as possible ensures that the measurement is taken at the point where the welding current enters the workpiece.

Deposition rate refers to the amount of weld metal that is deposited per minute in an arc welding process. It is a measure of the productivity and efficiency of the welding operation, indicating how quickly the weld joint is being filled. Filling rate, on the other hand, is not a commonly used term in welding and does not specifically refer to the amount of weld metal deposited. Weld deposition and weld duty cycle are also not the correct terms used for this measurement.

A double-U butt weld preparation is usually the most susceptible to lack of sidewall fusion during the manual arc process. This is because the shape of the double-U butt creates a larger gap between the two pieces being welded, making it more difficult for the filler material to fully penetrate and fuse with the sidewalls. As a result, there is a higher likelihood of incomplete fusion and potential defects in the weld joint.

The correct answer is the distance from the root to the face centre. In a fillet weld with equal leg lengths, the thickness is measured from the root, which is the point where the weld intersects the base metal, to the face centre, which is the midpoint of the weld. This measurement is important for determining the strength and integrity of the weld joint.

The leg length of a fillet weld refers to the distance from the root to the toe. This measurement is important as it determines the strength and quality of the weld joint. The leg length affects the load-bearing capacity and resistance to stress of the weld. Therefore, it is crucial to ensure that the leg length is appropriate and meets the design specifications to ensure a strong and durable weld.

The term "crater pipe" refers to a shrinkage defect found in the weld crater. In welding, a crater is the depression or cavity at the end of a weld bead. During the solidification process, if there is insufficient molten metal to fill the crater, it can result in a defect called a crater pipe. This defect appears as a void or cavity within the weld crater, which can weaken the weld and potentially lead to failure. Therefore, the correct answer is A.

None planar defects are defects that do not occur in a straight line or plane within the weld. These defects can include things like porosity, undercutting, or convexity. The statement "They are not usually as significant as planar defects" suggests that none planar defects are generally considered to be less severe or less critical compared to planar defects. This implies that while none planar defects may still require repair, they are not as detrimental to the overall integrity and strength of the weld as planar defects would be.

The term "weld junction" refers to the boundary between the fusion zone and the Heat Affected Zone (HAZ). This is the area where the weld metal and parent metal meet, and it is characterized by metallurgical changes that occur as a result of the heat from welding. The weld junction is an important area to consider in welding as it can impact the strength and integrity of the weld.

Deep weld craters/crater cracks are most likely to be caused by a welder with a poor technique in the MMA welding process. This can occur when the welder does not properly control the welding parameters, such as the arc length, travel speed, or current. As a result, excessive heat may be applied to the base metal, leading to the formation of deep craters or cracks in the weld.

The correct answer is "Combinations between two different weld types." Compound welds refer to joints that have combinations of welds made by different welding processes. This means that they can include both butt and fillet welds, as well as other combinations between two different weld types.

None of the above options are suitable for the repair welding of localized porosity in a butt weld. MMA (Manual Metal Arc) welding is a manual process and may not provide the precision required for repairing localized porosity. Mechanized MAG (Metal Active Gas) welding is also not suitable as it is typically used for continuous welding of long seams, not for localized repairs. Submerged arc welding is a process where the arc is submerged under a layer of flux, and it is not ideal for repairing localized porosity. Therefore, none of the above options are appropriate for this specific repair welding task.

A burn through occurs when the heat input during welding is excessive, causing the metal to melt through the joint. In this case, a root face that is too small would result in a smaller gap between the two pieces of metal to be welded. This smaller gap would restrict the flow of heat away from the weld, leading to an increased heat concentration and a higher likelihood of burn through. Therefore, a root face that is too small is most likely to cause a burn through.

Excessive root grinding and excessive back purge pressure can cause root concavity. When the root is ground excessively, it removes too much material, resulting in a concave shape. Additionally, excessive back purge pressure can lead to the entrapment of gas, which can further contribute to root concavity. Therefore, both factors combined can cause this issue during the welding process.

The strength of a fillet weld is primarily controlled by the design throat thickness. This refers to the theoretical thickness of the weld at its throat, which is the minimum distance between the root and face of the weld. The design throat thickness is determined by the size and shape of the weld, and it plays a crucial role in determining the overall strength and load-bearing capacity of the weld joint. Leg length and actual throat thickness are important factors in determining the quality and appearance of the weld, but they do not have as direct an impact on the strength as the design throat thickness.

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