CSWIP Multiple Choice Questions - Paper 1 Quiz

For a fabricated item that will be used in a high integrity application, it is crucial to conduct visual inspections at various stages. Inspecting before welding ensures that the materials and components are suitable for welding and that there are no defects or inconsistencies. During welding, inspections help to monitor the process and ensure that the welds are being executed correctly. Finally, inspecting after welding allows for the identification of any defects or issues that may have occurred during the welding process. By conducting inspections before, during, and after welding, the quality and integrity of the fabricated item can be assured.

The principal purpose of a welder qualification test is to evaluate and assess the skill level of the welder. This test is designed to measure the welder's ability to perform specific welding tasks and techniques, ensuring that they meet the required standards and specifications. It is used to determine if the welder possesses the necessary skills and knowledge to carry out welding activities safely and effectively. The test aims to validate the welder's competency and ensure that they are qualified to perform welding tasks in a professional and reliable manner.

When visually inspecting the root bead of a single V-butt weld, one should check for lack of root penetration. This refers to the situation where the weld does not fully penetrate the joint, resulting in a weak and incomplete bond. By checking for lack of root penetration, one can ensure the integrity and strength of the weld.

Overland pipeline welders are most likely to require continuous monitoring by a welding inspector because they are involved in welding pipelines that transport hazardous materials over long distances. The welding of these pipelines is critical to ensure their integrity and prevent leaks or failures that could have serious environmental and safety consequences. Continuous monitoring by a welding inspector helps to ensure that the welding is done properly and meets the necessary standards and regulations.

BS EN 970 allows the use of a magnifying glass for visual inspection and recommends a magnification range of x2 to x5. This means that the magnification should not be less than x2 or greater than x5. This range ensures that the inspector can adequately observe and assess the details of the inspected object without excessive magnification that may distort the image or make it difficult to interpret.

Heavy porosity on the surface of some MMA welds made on a construction site is most likely to be caused by moisture pick-up in the electrode covering. When electrodes absorb moisture, it creates steam during the welding process, which leads to the formation of porosity in the weld. This can result in weak and defective welds. Therefore, moisture pick-up in the electrode covering is the most probable cause of heavy porosity in MMA welds.

If a welding inspector detects a type of imperfection not allowed by the application Standard, he must reject the weld. This means that the weld does not meet the required standards and is deemed unacceptable. The inspector has the responsibility to ensure that the welding meets the necessary criteria and if it fails to do so, it must be rejected. The other options such as requesting further NDE or preparing a concession request may be applicable in different scenarios, but in this case, the correct action is to reject the weld.

The correct answer is "It requires more skill and increases the welders' qualification range." This is because unbacked joints require the welder to have more skill in order to achieve a proper weld. It also increases the welder's qualification range as they are able to demonstrate their ability to weld without the support of a backing material. The other options mentioned in the question are not valid reasons for why welder qualification tests are carried out using unbacked joints.

The Charpy impact test is commonly used to measure the toughness of weld metal, heat-affected zone (HAZ), and parent metal. This test involves striking a notched specimen with a pendulum hammer and measuring the energy absorbed during fracture. The amount of energy absorbed indicates the material's resistance to fracture and can be used to evaluate its toughness. Therefore, the Charpy impact test is a suitable mechanical test for assessing the toughness of these different metal regions.

The best destructive test for showing lack of sidewall fusion in a 25mm thickness butt weld is the side bend test. This test involves bending the welded specimen to assess the integrity of the fusion between the sidewalls. If there is a lack of fusion, cracks or separation will be visible on the bent surface, indicating a defect in the weld. The other options, such as nick break, Charpy impact, and face bend, are not specifically designed to assess sidewall fusion and may not provide accurate results in this case.

Slag inclusions are a common defect in welds and can occur in various welding processes. However, manual metal arc welding, also known as stick welding, is more prone to slag inclusions compared to other welding methods. This is because stick welding involves the use of a flux-coated electrode, which produces a slag layer that needs to be removed after each weld pass. If the slag is not properly removed, it can become trapped in the weld and result in slag inclusions. Therefore, slag inclusions may be present in manual metal arc welds.

The typical included angle for MMA welding a full penetration pipe butt joint is 70º. This angle is commonly used in this type of welding process to ensure proper penetration and fusion between the two pipe ends. It allows for sufficient access to the joint while maintaining a suitable angle for effective welding.

Grinding the toes of all welds helps to improve fatigue life. By blending in the welds, any stress concentration points or sharp edges are removed, which can reduce the likelihood of crack initiation and propagation. This helps to enhance the overall strength and durability of the weld, making it more resistant to fatigue failure over time.

Lack of sidewall fusion refers to a welding defect where the fusion between the weld metal and the base metal on the sidewall is incomplete. This can result in a weak joint and reduced structural integrity. It is considered a planar imperfection because it occurs along the plane of the sidewall and can be visually observed as a lack of fusion between the metal surfaces.

The fusion boundary of a fillet weld refers to the boundary between the weld metal and the Heat Affected Zone (HAZ). This is the area where the base metal has been heated to a high temperature during the welding process, causing changes in its microstructure. The fusion boundary is important because it indicates the extent to which the weld metal and the base metal have been effectively joined together. It is crucial for ensuring the strength and integrity of the weld joint.

Arc strikes are considered to be the most serious flaw when visually inspecting the face of a finished weld. Arc strikes occur when the welding electrode comes into contact with the base metal or previously deposited weld metal, causing localized overheating and potential damage to the base metal. This can result in weakened structural integrity and increased risk of failure in the welded joint. Therefore, arc strikes are a significant concern and should be avoided during the welding process.

A solid inclusion in a weld refers to any foreign material that becomes trapped within the weld during the welding process. This can include substances like slag, which is the byproduct of the welding process. Slag can form when impurities in the base metal or electrode react with the heat of the weld. When the slag becomes trapped within the weld, it can weaken the overall integrity of the weld joint. Therefore, the presence of entrapped slag is a possible explanation for a solid inclusion in a weld.

Sharpness would be a cause for rejection by most fabrication standards when inspecting fillet welds with undercut. This is because sharpness indicates that the weld has not been properly filled and smoothed, which can weaken the joint and increase the risk of failure. A smooth and rounded fillet weld is preferred as it ensures proper fusion and strength between the two pieces being joined.

The strength of a fillet weld is determined by the throat thickness. The throat thickness is the minimum distance from the root of the weld to the face of the weld, and it represents the effective area of the weld that resists the applied load. A larger throat thickness means a greater amount of material is available to resist the load, resulting in a stronger weld. Leg length, weld profile, and weld width are important factors in determining the quality and appearance of the weld, but they do not directly affect its strength.

Excessive amps refers to using a welding machine with a higher amperage setting than required for the specific welding job. This can lead to the formation of an undercut, which is a groove-like depression along the edge of the weld. The excessive heat generated by the high amperage causes the metal to melt and flow away from the weld, resulting in an insufficient fusion between the base metal and the weld metal. As a result, the undercut weakens the weld joint and reduces its overall strength.

A code of practice is a set of rules that provide guidelines and standards for manufacturing a specific product. These rules outline the procedures, techniques, and specifications that need to be followed during the manufacturing process to ensure consistency, quality, and safety. Codes of practice are commonly used in various industries to maintain uniformity and ensure that products meet the required standards and specifications.

In a bend test, the specimen is subjected to tension on one side (face) and compression on the other side (root). Therefore, the test is called a face bend.

Leg Length x 0.7 = Throat Thickness
Throat Thickness x 1.4 = Leg Length

Root gap refers to the distance between the edges of the two metal pieces being joined in a butt joint. In full penetration single-sided butt joints, the root gap plays a crucial role in determining the root bead penetration and profile. A larger root gap allows for deeper penetration of the root bead, resulting in a stronger and more secure joint. On the other hand, a smaller root gap may lead to insufficient penetration and weaker joint strength. Therefore, the root gap directly influences the quality and effectiveness of the joint in full penetration single-sided butt joints.

Although in many codes it is normal practice to measure Throat thickness, in the CSWIP examinations the correct answer in the syllabus is to measure Leg lengths.

The 8mm throat of a mitre fillet is the strongest because the throat size refers to the effective size of the weld, which is the critical factor in determining its strength. The leg size or excess weld metal does not contribute significantly to the strength of the weld. Therefore, the fillet weld with the smallest throat size, in this case, 8mm, would be the strongest.

Incomplete root fusion in a single V butt weld may be caused by linear misalignment. This means that the two pieces of metal being welded are not properly aligned in a straight line, causing a gap between the root faces. This misalignment prevents proper fusion of the metal, resulting in an incomplete weld. The other options, such as a too large root gap, too small root faces, or a welding current that is too high, may also contribute to welding issues, but in this case, linear misalignment is the most likely cause.

The correct answer is EN 970. EN 970 is the European Standard for Non-Destructive Examination (NDE) of fusion welds by visual examination. This standard provides guidelines and requirements for visually inspecting fusion welds to ensure their quality and integrity. It covers various aspects such as surface conditions, dimensions, and discontinuities that may affect the performance of the weld. Compliance with EN 970 ensures that visual examination of fusion welds is carried out consistently and effectively according to European standards.

Incomplete root penetration in a single V butt joint can be caused by both an excessive root face and the current settings being too low. An excessive root face refers to the distance between the root of the joint and the surface of the base metal, which can prevent proper fusion. Similarly, if the current settings are too low, there may not be enough heat generated to achieve complete penetration. Therefore, both factors can contribute to incomplete root penetration in a single V butt joint.

A burn-through may occur if the root gap is too large. When the root gap is too large, there is insufficient material to fill the gap during the welding process. As a result, the heat generated by the arc is concentrated on a smaller area, leading to excessive heat input and potential burn-through of the material being welded. It is important to maintain an appropriate root gap size to ensure proper weld penetration and avoid burn-through.