AWS Welder Testing & Quality Assurance 3 — Questions and Answers
Question 1: A production weld radiograph shows a rounded indication 3/32 inch in diameter in a 3/4-inch thick plate. Under AWS D1.1, this indication is:
- Acceptable — it is within the size limit for that thickness (Correct answer)
- Rejectable — any porosity is unacceptable
- Acceptable only if fewer than three pores are present
- Rejectable — rounded indications must be below 1/16 inch
Correct answer: Acceptable — it is within the size limit for that thickness
AWS D1.1 allows rounded indications up to 3/32 inch for base metal thicknesses between 1/2 inch and 1 inch.
Question 2: What is the purpose of a macro-etch test on a welder qualification sample?
- To visually evaluate cross-sectional weld profile, fusion, and internal discontinuities after etching (Correct answer)
- To measure the tensile strength of the weld
- To detect surface cracks using chemical reagents
- To verify the chemical composition of the filler metal
Correct answer: To visually evaluate cross-sectional weld profile, fusion, and internal discontinuities after etching
A macro-etch test reveals the weld cross-section after cutting and etching, allowing evaluation of fusion, penetration, and internal discontinuities.
Question 3: Which type of discontinuity is considered LINEAR in radiographic testing?
- Cracks (Correct answer)
- Porosity clusters
- Slag inclusions
- Tungsten inclusions
Correct answer: Cracks
Cracks are linear discontinuities because they have a significantly greater length-to-width ratio, making them especially dangerous stress concentrators.
Question 4: A welder is qualified using SMAW with an E7018 electrode. Can this qualification be used for GMAW production welding on the same base metal?
- No — each welding process requires separate qualification (Correct answer)
- Yes — the welder's skill transfers across all processes
- Yes — if the base metal thickness is identical
- No — only if the welder holds a 6G certification
Correct answer: No — each welding process requires separate qualification
Under AWS qualification standards, a change in welding process is an essential variable that requires the welder to requalify under the new process.
Question 5: What is the minimum face bend and root bend specimen width for a 3/4-inch thick plate qualification test per AWS D1.1?
- 1-1/2 inches (Correct answer)
- 3/4 inch
- 2 inches
- 1 inch
Correct answer: 1-1/2 inches
AWS D1.1 requires guided bend specimens to be at least 1-1/2 inches wide for plate thicknesses of 3/4 inch and above.
Question 6: A Charpy V-notch impact test is used in welder/procedure qualification. What property does this test primarily evaluate?
- Notch toughness and resistance to brittle fracture at a specified temperature (Correct answer)
- Ultimate tensile strength of the weld metal
- Fatigue resistance under cyclic loading
- Ductility measured by percent elongation
Correct answer: Notch toughness and resistance to brittle fracture at a specified temperature
Charpy V-notch tests measure the energy absorbed during fracture, indicating toughness and the material's resistance to brittle failure, especially at low temperatures.
Question 7: Under AWS D1.1, how long does a welder's qualification remain in effect if they have not welded with that process for 6 months?
- The qualification expires and the welder must requalify (Correct answer)
- The qualification remains valid indefinitely
- The qualification can be extended with a supervisor's letter
- The welder must pass only a visual examination to reactivate
Correct answer: The qualification expires and the welder must requalify
AWS D1.1 requires that a welder who has not used a welding process for a period exceeding 6 months must requalify for that process.
AWS Welder Testing & Quality Assurance 3
A production weld radiograph shows a rounded indication 3/32 inch in diameter in a 3/4-inch thick plate.
Under AWS D1.1, this indication is: