AWS Welder Testing & Quality Assurance 2 — Questions and Answers
Question 1: A welder fails a bend test because the coupon cracks at the root. What is the most likely cause?
- Incomplete fusion at the root (Correct answer)
- Excessive heat input
- Improper shielding gas composition
- Incorrect electrode polarity
Correct answer: Incomplete fusion at the root
Root cracks on bend tests typically indicate incomplete fusion or penetration at the root of the weld joint.
Question 2: Which AWS standard governs welder qualification for structural steel welding?
- AWS D1.1 (Correct answer)
- AWS D1.5
- AWS B2.1
- AWS D1.6
Correct answer: AWS D1.1
AWS D1.1 Structural Welding Code — Steel is the primary standard for qualifying welders on structural steel applications.
Question 3: What is the maximum number of guided bend test specimens that may show discontinuities exceeding 1/8 inch before the test is considered a failure?
- None — any such discontinuity is a failure (Correct answer)
- One specimen
- Two specimens
- Three specimens
Correct answer: None — any such discontinuity is a failure
Under AWS D1.1, any single discontinuity exceeding 1/8 inch in any direction on the convex surface constitutes a failed bend test.
Question 4: A radiographic test reveals elongated slag inclusions aligned parallel to the weld axis. What welding variable most likely caused this?
- Insufficient interpass cleaning (Correct answer)
- Too fast a travel speed
- Excessive preheat temperature
- Wrong base metal type
Correct answer: Insufficient interpass cleaning
Parallel slag inclusions typically result from slag trapped between passes due to inadequate interpass cleaning with a chipping hammer and wire brush.
Question 5: When performing a fillet weld break test, the weld is fractured to expose the cross-section. What defect would cause immediate failure?
- Incomplete fusion extending more than 20% of weld length (Correct answer)
- Weld reinforcement exceeding 1/8 inch
- A single pore smaller than 1/16 inch
- Slight undercut on the toe
Correct answer: Incomplete fusion extending more than 20% of weld length
Incomplete fusion beyond the allowable limit means the weld failed to bond properly to the base metal, which is a critical structural defect.
Question 6: Which position classification covers a welder qualified to weld in the overhead position on pipe?
- 6G
- 4G
- 2G
- 5G (Correct answer)
Correct answer: 5G
The 5G position is fixed pipe welded in the horizontal position with the axis horizontal, requiring all-position welding including overhead.
Question 7: What does the term 'essential variable' mean in the context of welder qualification?
- A variable whose change requires requalification of the welder (Correct answer)
- A variable that affects mechanical properties only
- A variable listed on the WPS that cannot be changed
- A variable controlled by the welding inspector
Correct answer: A variable whose change requires requalification of the welder
An essential variable in welder qualification is one that, when changed beyond allowed limits, requires the welder to requalify by retesting.
AWS Welder Testing & Quality Assurance 2
A welder fails a bend test because the coupon cracks at the root.
What is the most likely cause?