AWS Welding Inspection & Testing 4 — Questions and Answers
Question 1: During a magnetic particle inspection (MPI) of a fillet weld, indications appear only when the magnetic field is perpendicular to a discontinuity. What is the recommended practice to ensure complete coverage?
- Magnetize in two directions at least 45° apart (Correct answer)
- Magnetize in one direction only along the weld axis
- Apply the magnetic field parallel to the weld toe
- Use DC current exclusively for all fillet welds
Correct answer: Magnetize in two directions at least 45° apart
Magnetizing in two directions at least 45° apart (typically 90°) ensures that discontinuities oriented in any direction will be detected.
Question 2: A radiographic image shows a dark, elongated linear indication with fuzzy edges inside the weld. This is most likely indicative of:
- Incomplete fusion
- Porosity
- Slag inclusion (Correct answer)
- Tungsten inclusion
Correct answer: Slag inclusion
Slag inclusions appear as dark, elongated linear indications with irregular or fuzzy edges in radiographic images.
Question 3: When performing a guided bend test, the coupon cracks at the weld toe on the tension side. This result indicates:
- Lack of fusion at the weld toe (Correct answer)
- Excessive reinforcement height
- Incomplete joint penetration at the root
- Porosity at the centerline
Correct answer: Lack of fusion at the weld toe
Cracking at the weld toe during a guided bend test indicates lack of fusion between the weld metal and base metal at that location.
Question 4: AWS D1.1 requires that the inspector verify the preheat temperature at what minimum distance from the joint edge before welding begins?
- 3 inches (75 mm) (Correct answer)
- 1 inch (25 mm)
- 6 inches (150 mm)
- 2 inches (50 mm)
Correct answer: 3 inches (75 mm)
AWS D1.1 requires preheat to be verified at a minimum distance of 3 inches (75 mm) from the point of welding on each side of the joint.
Question 5: A liquid penetrant inspection is performed on a stainless steel weld. After removing the excess penetrant, the developer is applied. What does the absence of any indications confirm?
- No surface-breaking discontinuities are present (Correct answer)
- No subsurface discontinuities are present
- The weld meets all volumetric acceptance criteria
- No cracks exist anywhere in the base metal
Correct answer: No surface-breaking discontinuities are present
Liquid penetrant testing is a surface NDT method and only confirms the absence of surface-breaking discontinuities; it cannot detect subsurface defects.
Question 6: When reviewing a Procedure Qualification Record (PQR), the inspector notes the base metal used was P-1 Group 2. The WPS being supported lists P-1 Group 1 base metal. Under ASME Section IX, is this PQR valid for the WPS?
- Yes, because both are P-1 metals and qualification covers the P-number (Correct answer)
- No, because the group numbers must match exactly
- Yes, but only for thicknesses under 1 inch
- No, unless the welder also re-qualifies
Correct answer: Yes, because both are P-1 metals and qualification covers the P-number
Under ASME Section IX, qualification of a P-number covers all base metals within that P-number regardless of group number, unless impact testing is required.
Question 7: An ultrasonic examination report shows a reflector at 60% DAC (Distance Amplitude Correction). Per AWS D1.1, what action is required?
- Record the indication but it is acceptable without further evaluation (Correct answer)
- Reject the weld immediately
- Perform radiographic testing to confirm
- Grind and re-weld the area
Correct answer: Record the indication but it is acceptable without further evaluation
Under AWS D1.1, indications below 20% DAC are acceptable without recording; those at 20–100% DAC must be recorded, but only those exceeding 100% DAC require rejection.
AWS Welding Inspection & Testing 4
During a magnetic particle inspection (MPI) of a fillet weld, indications appear only when the magnetic field is perpendicular to a discontinuity.
What is the recommended practice to ensure complete coverage?