AWS AWS D1.1 Structural Welding Code 5 — Questions and Answers
Question 1: AWS D1.1 requires that groove weld root openings exceeding the code tolerance by more than 1/16 in (1.6 mm) but not more than 1/4 in (6 mm) must be:
- Rejected and the joint re-cut
- Built up with weld metal before final welding (Correct answer)
- Filled with backing material only
- Reported to the engineer but left as-is
Correct answer: Built up with weld metal before final welding
AWS D1.1 allows oversized root openings up to 1/4 in to be corrected by building up the joint edges with weld metal before proceeding with final welding.
Question 2: In AWS D1.1, the term 'essential variable' in a welding procedure specification refers to a variable whose change requires:
- Only a WPS revision with no additional testing
- Requalification of the WPS by welding and testing (Correct answer)
- Notification to the inspector only
- A change in base metal classification
Correct answer: Requalification of the WPS by welding and testing
Essential variables are those that significantly affect weld mechanical properties; changing them requires complete WPS requalification through testing per AWS D1.1 Clause 4.
Question 3: According to AWS D1.1, which type of weld joint is prohibited from being used as a prequalified joint for primary tension members in cyclically loaded structures?
- CJP groove welds with backing bars left in place (Correct answer)
- PJP groove welds with flush reinforcement
- Fillet welds on lapped joints
- CJP welds with back gouging
Correct answer: CJP groove welds with backing bars left in place
AWS D1.1 prohibits steel backing bars left in place on CJP groove welds in primary tension members of cyclically loaded structures due to stress concentration.
Question 4: When AWS D1.1 specifies radiographic testing (RT) acceptance criteria, which measurement is used to evaluate elongated porosity (worm tracks)?
- Total projected area
- Maximum length in any 12-inch weld segment (Correct answer)
- Diameter of the largest individual pore
- Density ratio compared to base metal
Correct answer: Maximum length in any 12-inch weld segment
AWS D1.1 evaluates elongated slag inclusions and porosity by their maximum length within any 12-inch (300 mm) length of weld.
Question 5: Under AWS D1.1, a welder who fails a qualification test in the 2G (horizontal) position is:
- Permanently disqualified from that process
- Allowed to immediately retest without restriction
- Required to receive additional training before retesting (Correct answer)
- Qualified only for flat position welding
Correct answer: Required to receive additional training before retesting
AWS D1.1 Clause 4 states that a welder who fails a qualification test must receive additional training or practice before being retested.
Question 6: AWS D1.1 defines the 'heat-affected zone' (HAZ) as the portion of the base metal that has not been melted but whose microstructure has been altered by what minimum temperature?
- 400°F (204°C)
- 1000°F (538°C)
- 1350°F (732°C) (Correct answer)
- 2000°F (1093°C)
Correct answer: 1350°F (732°C)
The HAZ is the base metal zone heated above approximately 1350°F (732°C), the lower critical transformation temperature, causing microstructural changes without melting.
Question 7: According to AWS D1.1, which of the following conditions requires magnetic particle testing (MT) or liquid penetrant testing (PT) in addition to visual inspection for weld repair areas?
- Any weld repaired due to undercut exceeding 1/32 in
- Repairs to cracks in tension zones of cyclically loaded structures (Correct answer)
- Slag removal from completed welds before painting
- Tack weld removal from non-critical members
Correct answer: Repairs to cracks in tension zones of cyclically loaded structures
AWS D1.1 requires MT or PT after crack removal and repair in tension zones of cyclically loaded structures to verify complete crack elimination before rewelding.
AWS AWS D1.1 Structural Welding Code 5
AWS D1.1 requires that groove weld root openings exceeding the code tolerance by more than 1/16 in (1.6 mm) but not more than 1/4 in (6 mm) must be: