AWS Welding Inspection & Testing 5 — Questions and Answers
Question 1: During visual inspection of a completed groove weld on a structural steel joint, the inspector measures the weld face and finds the width varies significantly along its length. What potential quality issue does this most likely indicate?
- Inconsistent travel speed or torch angle during welding (Correct answer)
- Incorrect base metal chemistry
- Underfill at the weld root
- Excessive preheat temperature
Correct answer: Inconsistent travel speed or torch angle during welding
Inconsistent weld face width along a groove weld is a direct result of variations in travel speed or torch/electrode angle during the welding process.
Question 2: A fillet weld is measured with a fillet weld gauge and found to be 5/16 inch, but the WPS requires a 3/8-inch fillet weld. The inspector should:
- Reject the weld and require additional weld metal to meet the specified size (Correct answer)
- Accept the weld since 5/16 is within one standard size
- Accept the weld if visual inspection shows no other defects
- Require re-welding the entire joint from scratch
Correct answer: Reject the weld and require additional weld metal to meet the specified size
An undersized fillet weld does not meet the WPS requirements and must be rejected; the welder must add weld metal to achieve the specified 3/8-inch size.
Question 3: When performing radiography on a pipe weld, an image quality indicator (IQI) is placed on the source side of the weld. The purpose of the IQI is to:
- Verify that the radiographic technique has adequate sensitivity to detect relevant discontinuities (Correct answer)
- Measure the actual size of any indications found
- Confirm the weld meets tensile strength requirements
- Determine the chemical composition of the weld metal
Correct answer: Verify that the radiographic technique has adequate sensitivity to detect relevant discontinuities
An IQI (penetrameter) demonstrates that the radiographic technique has sufficient sensitivity and image quality to detect discontinuities of a specified size.
Question 4: A welder qualification test plate is submitted for a transverse tensile test. The specimen fractures in the base metal at a load that produces a tensile stress of 72,000 psi, while the base metal's minimum specified tensile strength is 70,000 psi. The test result is:
- Acceptable, because fracture in the base metal at or above the minimum specified strength meets the requirement (Correct answer)
- Unacceptable, because the fracture did not occur in the weld metal
- Acceptable only if the weld metal exhibits 100% joint efficiency
- Unacceptable unless a second specimen is tested
Correct answer: Acceptable, because fracture in the base metal at or above the minimum specified strength meets the requirement
A tensile specimen that fractures in the base metal at or above the minimum specified tensile strength is considered a passing result, as the weld itself is stronger than the base metal.
Question 5: When using the dye penetrant method, the maximum allowable time between applying the developer and reading the indications per ASME standards is typically:
- 60 minutes (Correct answer)
- 10 minutes
- 5 minutes
- 120 minutes
Correct answer: 60 minutes
Indications must generally be read within 60 minutes of developer application to avoid bleeding that could obscure or distort the indication's true size.
Question 6: An inspector is verifying interpass temperature on a multi-pass weld. The WPS specifies a maximum interpass temperature of 400°F. The inspector measures 425°F before the next pass is initiated. The correct course of action is:
- Stop welding and allow the weld to cool to 400°F or below before continuing (Correct answer)
- Proceed immediately since 25°F over is within acceptable tolerance
- Increase the preheat to compensate for the elevated temperature
- Apply post-weld heat treatment immediately to restore properties
Correct answer: Stop welding and allow the weld to cool to 400°F or below before continuing
Exceeding the maximum interpass temperature specified in the WPS requires the welder to stop and allow cooling, as excessive interpass temperature can degrade mechanical properties and grain structure.
Question 7: A welding inspector discovers that the certified mill test report (CMTR) for a heat of base metal cannot be located prior to welding. Under AWS D1.1, the inspector should:
- Require material testing or documentation to verify the material meets the specified requirements before allowing welding to proceed (Correct answer)
- Allow welding to proceed if the material is visually similar to the specified material
- Accept a verbal confirmation from the fabricator that the material is correct
- Allow welding and obtain the CMTR after completion
Correct answer: Require material testing or documentation to verify the material meets the specified requirements before allowing welding to proceed
Traceability of base metal to its certified mill test report is required; welding should not proceed on unverified material until proper documentation or testing confirms the material specification.
AWS Welding Inspection & Testing 5
During visual inspection of a completed groove weld on a structural steel joint, the inspector measures the weld face and finds the width varies significantly along its length.
What potential quality issue does this most likely indicate?