CSWIP 3.1 Certification Exam Prep Test

The correct answer is "only in accordance with WPS." This means that preheating the base metal before welding is not always necessary. Instead, it should be done only if it is specified in the Welding Procedure Specification (WPS). The WPS provides guidelines for welding processes and procedures, including preheating requirements. So, whether or not preheating is necessary depends on the specific welding procedure outlined in the WPS.

The correct answer is dip, spray, pulse. When using MIG/MAG (GMAW) welding, there are three metal transfer modes. The dip transfer mode occurs at low current and voltage, where the wire tip touches the weld pool and small droplets are transferred. The spray transfer mode happens at high current and voltage, where the wire tip is continuously fed into the weld pool, creating a fine spray of molten metal. The pulse transfer mode involves alternating between high and low current levels, resulting in controlled droplet transfer. These three transfer modes offer different benefits and are used in different welding applications.

It is important to ensure that all meters, instruments, and controls on the welding machine are functioning properly and have up-to-date calibration certificates. If they are not functioning properly and their calibration certificates are out of date, it is necessary to stop welding until corrective measures are completed to rectify the situation. This will ensure the accuracy and safety of the welding process.

If a welder is found using incorrect welding consumable, the appropriate cause of action would be to report the incident and record it with relevant information. This is important to ensure that the incident is documented and can be addressed appropriately. Allowing the welding to proceed if the workmanship is good may not be advisable as it could compromise the quality and integrity of the weld. Similarly, if the tensile strength of the consumable is the same as the approved, it does not justify using incorrect consumables. Therefore, the best course of action is to report the incident and maintain a record for future reference.

It is important to raise the issue with the QC department supervisor because the welding supervisor's insistence that the unacceptable welds are acceptable goes against the quality control standards. The QC department supervisor is responsible for ensuring that all products meet the required quality standards, so they should be made aware of the situation. Accepting the unacceptable welds without addressing the issue could compromise the quality of the final product and potentially lead to further problems down the line.

The correct answer is 5oC - 60oC. This temperature range is typically suitable for the application of liquid penetrant. Temperatures below 5oC may cause the penetrant to freeze or become less effective, while temperatures above 60oC may cause the penetrant to evaporate or degrade. Therefore, the recommended temperature range ensures optimal performance and accurate results during the penetrant testing process.

Slag lines found in MMA welds are usually associated with improper cleaning between weld runs. When welding, it is important to remove any slag or impurities from the previous weld before starting a new one. If this cleaning step is not done properly, slag can be trapped between the weld runs, leading to the formation of slag lines. These lines can weaken the weld and reduce its overall quality. Therefore, it is essential to ensure thorough cleaning between weld runs to avoid the presence of slag lines.

The distance from the surface to the eye should be a maximum of 600mm in order to assess the surface of a weld for direct inspection. This distance allows for a closer and more detailed examination of the weld, ensuring that any potential defects or imperfections can be properly identified and evaluated. A longer distance may result in reduced visibility and make it more difficult to accurately assess the quality of the weld.

Slag in the toes of a weld can potentially mask any discontinuity or defect in the weld. It is important to have the welder remove the slag to ensure that the weld is thoroughly inspected for any potential issues. This will help to maintain the quality and integrity of the fillet weld.

A standard radiographic film test is not capable of adequately detecting lamination in rolled plate adjacent to the weld. This is because lamination refers to the separation or splitting of layers in the rolled plate, which may not be easily visible on a radiographic film. The test is more effective in detecting porosity in the weld volume, slag inclusion in a weld, and lack of root penetration in a weld, as these issues can be identified through the use of radiographic imaging.

All of the given options - heating, contraction, and stress - can cause distortion. Heating can cause expansion of materials, leading to changes in shape and size, resulting in distortion. Contraction, on the other hand, can cause materials to shrink or contract, also leading to distortion. Stress, whether it is caused by external forces or internal factors, can cause materials to deform or warp, causing distortion. Therefore, all of these factors have the potential to cause distortion.

The depletion of chromium in austenitic stainless steel will result in the formation of chromium oxide. Chromium is a key element in stainless steel as it helps in forming a protective oxide layer on the surface, which prevents corrosion. When chromium is depleted, this protective layer is compromised, making the grain structure vulnerable to corrosion. Therefore, the formation of chromium oxide is crucial for maintaining the integrity of the stainless steel.

The hardness value becomes a problem when it is in the range of 300 to 350 HV. This range indicates a high level of hardness, which increases the risk of heat-affected zone (HAZ) cracking. HAZ cracking occurs during welding or other high-temperature processes, and it can lead to structural integrity issues. Therefore, minimizing the risk of HAZ cracking requires keeping the hardness value below 300 to 350 HV.

Radiographic testing, also known as X-ray testing, is a nondestructive testing method that uses X-rays or gamma rays to inspect the internal structure of a component. It is able to detect defects such as cracks, voids, and inclusions. Unlike other NDT methods, radiographic testing provides a clear image of the component's internal structure, eliminating the need for post inspection cleaning or further treatment. Therefore, radiographic testing does not require any additional steps after the inspection process.

The percentage elongation can be calculated by subtracting the initial length from the final length, dividing it by the initial length, and then multiplying by 100. In this case, the initial length is 120mm and the final length is 135mm. So, the percentage elongation would be (135-120)/120 * 100 = 12.5%.

Hydrogen cracking, also known as cold cracking, occurs when hydrogen atoms become trapped in the weld metal and cause cracks to form. These cracks typically occur during the cooling process of the weldment. The correct answer, 300oC, indicates that hydrogen cracking will not form until the weldment cools to a temperature below 300 degrees Celsius. At this temperature, the risk of hydrogen cracking significantly increases, making it important to control the cooling rate and minimize the presence of hydrogen during the welding process.

Ultrasonic testing is the most suitable NDE (Non-Destructive Examination) process for detecting internal lack of sidewall fusion on a MAG (Metal Active Gas) weld. Ultrasonic testing uses high-frequency sound waves to detect flaws or inconsistencies in the material being tested. It is capable of penetrating through the weld and can accurately identify any lack of fusion within the sidewall. Visual inspection may not be able to detect internal flaws, dye penetrant testing is more suitable for surface defects, and radiography may not provide the same level of detail as ultrasonic testing for this specific type of flaw.

Using the minimum number of runs will help to reduce distortion because it minimizes the amount of heat input and thermal cycling that occurs during the welding process. Distortion is often caused by the unequal heating and cooling of the material, and by reducing the number of runs, the overall heat input is reduced, resulting in less distortion.

Solidification cracking, also known as hot cracking or liquation cracking, occurs immediately after welding in carbon steels. During the welding process, the metal undergoes a rapid cooling and solidification phase. This rapid cooling can cause the formation of brittle microstructures and the development of high stresses. If the metal is unable to accommodate these stresses, cracks can form in the weld zone. Therefore, solidification cracking is most likely to occur immediately after welding, when the metal is still in a highly susceptible state.

Thoriated tungsten electrodes have the major disadvantage of being radioactive in nature. This means that they emit radiation, which can be harmful to human health and the environment. This poses a risk for workers who handle these electrodes and for anyone who is exposed to them. It is important to handle and dispose of thoriated tungsten electrodes properly to minimize the potential risks associated with their radioactive nature.

When H2 (hydrogen) is present in a concentration of over 15ml/100gr of weld metal deposited, it is considered to be more critical in cracking. This indicates that a high level of hydrogen is present in the weld metal, which increases the risk of hydrogen-induced cracking. The higher the concentration of hydrogen, the greater the likelihood of cracking occurring in the weld. Therefore, it is important to monitor and control the hydrogen content in weld metal to prevent cracking.

When performing ultrasonic testing on weld metal made by MMA, it is essential to clean the surrounding parent metal adjacent to the weld. This is because spatter, which is the molten metal expelled during the welding process, could impact the contact of the probe with the parent metal surface. If the spatter is not removed, it may create a barrier between the probe and the parent metal, affecting the accuracy of the ultrasonic testing results. Therefore, cleaning the parent metal helps ensure proper contact and reliable testing.

The minimum interpass temperature would be the preheat temperature. Preheating is done before welding to reduce the cooling rate of the weld and prevent the formation of brittle microstructures. The preheat temperature is typically specified in the welding procedure specification (WPS) and is considered the minimum temperature that should be maintained during welding. Therefore, the preheat temperature would also be the minimum interpass temperature.

A Welding Procedure Specification (WPS) is a written document that provides detailed instructions and guidelines for performing welding operations. It includes information such as welding parameters, materials to be welded, welding positions, and post-weld heat treatment requirements. A WPS ensures that welding procedures are consistently followed to achieve the desired quality and integrity of welded joints.

The correct answer is 600oC. Stress relieving is a heat treatment process used to reduce residual stresses in materials, including carbon steel. The typical temperature for stress relieving carbon steel is around 600oC. At this temperature, the steel undergoes a transformation that helps to relieve internal stresses and improve its mechanical properties. Higher temperatures may cause excessive grain growth, while lower temperatures may not be sufficient to fully relieve the stresses. Therefore, 600oC is the most suitable temperature for stress relieving carbon steel.

Increasing the volume of weld metal deposited can lead to increased residual stress in the joint. Residual stress refers to the stress that remains in a material even after the external forces are removed. This can occur due to the uneven heating and cooling during the welding process. Increased residual stress can have negative effects on the joint, such as distortion, cracking, and reduced fatigue life. Therefore, the statement suggests that increased residual stress is a potential consequence of using a high volume of weld metal, rather than a benefit.

Quenching hardening is the heat treatment used to create a high strength but brittle microstructure. During quenching hardening, the material is heated to a high temperature and then rapidly cooled by immersing it in a quenching medium such as oil or water. This rapid cooling causes the formation of a hardened microstructure, which increases the material's strength but also makes it more brittle. This heat treatment is commonly used for materials that require high strength, such as tool steels, but may not be suitable for applications where toughness and ductility are important.

Surface breaking planar imperfections are generally considered to be the most serious because they are defects that extend across the surface and have a planar shape. These imperfections can weaken the structure and compromise its integrity, making it more susceptible to failure. They are easily detectable and can lead to significant damage if not addressed promptly. Root concavity, buried planar, and surface breaking non-planar imperfections may also have negative effects, but surface breaking planar imperfections are typically the most severe.

In Non-Destructive Testing (NDT), prod is used in Magnetic Particle Testing (MPI) to create a magnetic field on the test surface, helping to detect surface and near-surface flaws. Prods are placed directly on the material to induce a magnetic field. On the other hand, probe is used in Ultrasonic Testing (UT) to send and receive ultrasonic waves. The probe generates high-frequency sound waves that reflect off internal flaws, helping to locate and assess defects within the material.

The minimum preheat temperature should be measured immediately prior to commencing the first pass and subsequent passes. This is because preheating is done to reduce the risk of hydrogen cracking and to ensure proper weld quality. By measuring the temperature right before starting each pass, the welder can ensure that the preheat temperature is maintained throughout the welding process, minimizing the risk of defects in the weld.

Increasing the voltage on the SAW (Submerged Arc Welding) set would result in a wider weld width. This is because higher voltage leads to increased heat input, causing the weld pool to become larger and resulting in a wider weld bead.

The correct answer is "none if they were in a sealed vacuum pack immediately prior to use." This means that if the electrodes were stored in a sealed vacuum pack until just before they are used, no pre-treatment is necessary. This is because the sealed vacuum pack helps to maintain the quality and integrity of the electrodes, preventing any contamination or oxidation that would require pre-treatment.

A quantitative test is a test that provides numerical data or measurements. The tensile test is a type of mechanical test that measures the strength and elasticity of a material by subjecting it to tension. This test involves applying a controlled force to a specimen until it breaks, and the resulting data is used to determine various mechanical properties such as yield strength, ultimate tensile strength, and elongation. Therefore, the tensile test is considered a quantitative test as it provides numerical data for analysis and comparison.

The main cause of lack of root penetration during root weld is the current being too low. When the current is insufficient, it does not provide enough heat to melt and fuse the root properly, resulting in poor penetration. This can lead to weak welds and potential structural issues. The other options mentioned, such as the root gap being too large, preheat not being used, or the root face being too small, can also contribute to welding issues, but the current being too low is the most significant factor in this case.

Using heat treatment equipment with thermocouples attached and a chart recorder is the most accurate method of ensuring that the correct preheat is applied. This method allows for precise temperature monitoring and recording throughout the heating process. The thermocouples measure the actual temperature, and the chart recorder provides a visual representation of the temperature over time. This ensures that the desired preheat temperature is reached and maintained consistently, minimizing the risk of overheating or underheating the material.

Clustered porosity refers to a group of small pores or voids that are closely spaced together in a weld. These pores are difficult to size correctly when using ultrasonic testing because they are small and closely packed, making it challenging to distinguish individual pores from each other. Additionally, the proximity of the pores can cause acoustic interference, further complicating the sizing process. Therefore, clustered porosity is the most difficult defect to accurately size when using ultrasonic testing on a weld.

Both EN ISO 22553 and AWS A2.4 have the same rule for depicting "weld all around". This means that in both standards, the symbol used to represent a weld that extends all the way around a joint is the same. This similarity ensures consistency and clarity in communication between welders and engineers using either standard.

If the recorded hardness figures were 5HV points over the maximum permitted, the appropriate course of action would be to request a retest. This is because the results are slightly above the permitted value, indicating a potential error or inconsistency in the initial test. By requesting a retest, it allows for a second evaluation to confirm the accuracy of the hardness figures and ensure compliance with the permitted standards.

A 4T bend is not more severe than a 2T bend. In fact, the opposite is true. In a bend test, the "T" refers to the thickness of the specimen being bent. So a 2T bend means that the specimen is bent over a radius equal to twice its thickness, while a 4T bend means that the specimen is bent over a radius equal to four times its thickness. The larger the radius, the less severe the bend. Therefore, a 4T bend is less severe than a 2T bend.

When all of the answers indicated are true, it means that a weld all around symbol is not required in any of the mentioned scenarios. This symbol is typically used to indicate that a weld is required to extend all the way around the joint. However, in the case of a circumferential joint, a pipe to pipe butt weld, or a nozzle to shell weld, the weld is already implied to be all around and therefore the symbol is not necessary.

When TIG welding with AC, the high heating effect in the electrode causes it to wear down quickly. Therefore, it is necessary to lightly grind the tungsten electrode to a slight chamfer, removing only the corners. This helps to maintain a stable arc and prevent the electrode from overheating and melting too quickly. Grinding the electrode to a fine vertex angle or using it straight from the packet without grinding would not be ideal as it would result in poor arc stability and premature electrode failure. Baking the electrode at 300oC for an hour before use is not necessary for AC welding and would not have any significant impact on its performance.

In SAW (Submerged Arc Welding), using AC (Alternating Current) can help avoid the problem of arc blow. Arc blow is a phenomenon where the welding arc is deflected or deviated from its intended path due to magnetic fields or other factors. By using AC, the direction of the magnetic fields can be constantly changing, reducing the chances of arc blow occurring. This helps in maintaining a stable and controlled welding arc, resulting in a better quality weld.

The ultimate tensile strength value is 377 N/mm2. This can be determined by dividing the maximum load applied (170kN) by the cross-sectional area (30mm x 15mm = 450mm2).

Weld decay is caused by the formation of a compound with carbon, and the other element in this compound is chromium. Chromium forms a compound with carbon called chromium carbide, which can cause weld decay when it precipitates along the grain boundaries of the weld. This can lead to a loss of corrosion resistance and mechanical properties in the affected area.

The CTOD test measures the material property known as fracture toughness. Fracture toughness is the ability of a material to resist the growth of cracks under applied stress. The CTOD test, also known as the Crack Tip Opening Displacement test, involves applying a controlled load to a pre-cracked specimen and measuring the displacement at the crack tip. This test provides valuable information about the material's resistance to crack propagation and its ability to withstand brittle fracture.

In the given scenario, it is important to insist on using the same type of flux that is approved by the Welding Procedure Specification (WPS). Even though the classification for both agglomerated and fused flux is the same, they have been tested under different parameters and conditions. Therefore, using a different type of flux without proper approval from the WPS can lead to variations in the welding process and potentially compromise the quality and integrity of the weld. It is necessary to follow the approved procedures to ensure consistency and adherence to standards.

The correct sequence for the PWHT chart is as follows: unrestricted heating rate, restricted heating rate, soak time, restricted cooling rate, unrestricted cooling rate. This sequence ensures that the material is heated at a controlled rate, held at a specific temperature for a certain period of time, and then cooled down gradually to prevent any thermal stresses or distortions. By following this sequence, the material can be effectively treated during PWHT.

According to AWS A2.4, the symbol for welding on the arrow side should be placed below the solid line. This indicates that the weld should be made on the side of the joint where the arrow is pointing. The placement of the symbol below the solid line helps to clearly identify the intended location for the weld.

In a fillet weld fracture test, the specimen is broken with the fillet weld in compression. This means that the force applied to the specimen is directed towards the weld, compressing it. This type of testing is commonly used to evaluate the strength and quality of fillet welds, as it simulates the conditions that the weld would experience in real-life applications. By breaking the specimen in compression, any weaknesses or defects in the weld can be identified and analyzed.