AWS AWS Welder Qualification & Procedure Testing 5 — Questions and Answers
Question 1: A welder's certification under AWS D1.1 expires if the welder has not welded with the qualified process for more than:
- 6 months (Correct answer)
- 1 year
- 90 days
- 2 years
Correct answer: 6 months
AWS D1.1 Clause 4.5 states that a welder's qualification expires if they have not used the process for more than 6 months.
Question 2: Which of the following is NOT considered an essential variable for a welder qualification test under AWS D1.1?
- Preheat temperature (Correct answer)
- Change in welding position
- Change from backing to no backing
- Change in weld process
Correct answer: Preheat temperature
Preheat temperature is an essential variable for WPS qualification but is generally not listed as an essential variable for welder performance qualification.
Question 3: When performing a nick-break test on a fillet weld, the acceptance criterion requires that the exposed fracture surface show:
- Complete fusion with no porosity larger than 3/32 inch in any dimension (Correct answer)
- Zero porosity of any kind
- Porosity less than 1/4 inch in diameter
- No cracks but allows slag inclusions up to 1/8 inch
Correct answer: Complete fusion with no porosity larger than 3/32 inch in any dimension
AWS D1.1 requires the nick-break fracture surface to show complete fusion and limits any single pore to 3/32 inch with restrictions on total porosity area.
Question 4: Under AWS D1.1, a welder who qualifies with FCAW-S (self-shielded) is also qualified to weld with:
- FCAW-S only; it does not qualify FCAW-G (Correct answer)
- Both FCAW-S and FCAW-G
- SMAW in all positions
- GMAW short-circuit transfer
Correct answer: FCAW-S only; it does not qualify FCAW-G
FCAW-S and FCAW-G are treated as separate processes under AWS D1.1 welder qualification because their shielding mechanisms differ.
Question 5: What does the 'F-number' classify in AWS welder and procedure qualification?
- Filler metal groupings based on usability characteristics (Correct answer)
- Base metal groupings by chemical composition
- Flux type and slag viscosity
- Preheat and interpass temperature ranges
Correct answer: Filler metal groupings based on usability characteristics
F-numbers group filler metals by their usability and welding characteristics, allowing qualification with one filler to cover others in the same group.
Question 6: During a groove weld procedure qualification test, side bend specimens are required instead of face and root bends when the base metal thickness is:
- Greater than 3/8 inch (Correct answer)
- Less than 3/8 inch
- Exactly 1/4 inch
- Greater than 1 inch only
Correct answer: Greater than 3/8 inch
AWS D1.1 requires side bend specimens when the plate thickness exceeds 3/8 inch because face and root bends may not adequately sample the full weld cross-section.
Question 7: A CWI reviewing a welder qualification test coupon notices the face bend specimen cracked at the edge outside the weld zone. This result is:
- Acceptable if no other cracks exceed 1/8 inch on the tension surface (Correct answer)
- Cause for immediate rejection of the entire test
- Acceptable only if the base metal is low-alloy steel
- Requires a supplemental macro-etch test before accepting
Correct answer: Acceptable if no other cracks exceed 1/8 inch on the tension surface
AWS D1.1 permits disregarding edge cracks on bend specimens if no other crack on the tension surface exceeds 1/8 inch, provided the edge crack did not originate from a slag inclusion or other defect.
AWS AWS Welder Qualification & Procedure Testing 5
A welder's certification under AWS D1.1 expires if the welder has not welded with the qualified process for more than: