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Weld Discontinuities & Defects Flashcards

7 cards from real AWS practice questions. Tap to flip, then mark Knew It or Still Learning — missed cards come back until you master them.

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  1. A weld cross-section shows weld metal that has rolled over the base metal surface without fusing to it. This discontinuity is called:

    Answer: Overlap

    Overlap (also called cold lap) occurs when weld metal flows over the base metal surface and solidifies without achieving fusion, creating a notch-like condition.

  2. Which type of porosity is characterized by a single large void elongated along the weld axis?

    Answer: Wormhole (piping) porosity

    Wormhole or piping porosity consists of elongated tubular voids that form parallel to the weld axis due to gas escaping during solidification.

  3. During multi-pass welding, which action is MOST important to prevent inter-pass slag inclusions?

    Answer: Thoroughly removing slag between passes

    Thorough slag removal between passes prevents slag from being trapped under subsequent weld beads, which would create slag inclusions.

  4. Incomplete joint penetration (IJP) in a groove weld is MOST commonly caused by:

    Answer: Insufficient groove angle or root opening

    Insufficient groove angle or inadequate root opening prevents the arc from reaching the root of the joint, resulting in incomplete joint penetration.

  5. Which of the following BEST describes a 'cold crack' in welding?

    Answer: A crack that forms at or near room temperature after the weld has cooled

    Cold cracks (hydrogen-induced cracks) form at or near room temperature after the weld cools, driven by hydrogen, residual stress, and a susceptible microstructure.

  6. A radiograph shows a dark, rounded indication with a fuzzy outline at the center of a weld bead. This is MOST likely:

    Answer: Gas porosity

    Gas porosity appears as rounded, dark indications with relatively smooth edges on a radiograph because the spherical void absorbs less radiation than surrounding metal.

  7. Which discontinuity is UNIQUE to gas tungsten arc welding (GTAW) and not found in other arc welding processes?

    Answer: Tungsten inclusion

    Tungsten inclusions are unique to GTAW because the non-consumable tungsten electrode can contaminate the weld pool if it contacts the molten metal or is improperly sized.